Factory Workshop Manual
Make
Ford
Model
Crown Victoria
Engine and year
V8-4.6L CNG SOHC VIN 9 (1999)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 )
P0720 - P0724: Testing and Inspection P0720 ( P 0720 )
Manual Transmission (M.T.)
For diagnosis of P0720 refer to chart
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 9
For complete Engine Control diagnostic information, See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Automatic Transmission (A.T.)
For diagnosis of P0720 refer to chart
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page
10
3 Of 7
For complete Transmission Control diagnostic information, See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
For complete Engine Control diagnostic information, See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page
11
P0720 - P0724: Testing and Inspection P0721 ( P 0721 )
Manual Transmission (M.T.)
For diagnosis of P0721 refer to chart
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page
12
For complete Engine Control diagnostic information, See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Automatic Transmission (A.T.)
For diagnosis of P0721 refer to chart
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page
13
3 Of 7
For complete Transmission Control diagnostic information, See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
For complete Engine Control diagnostic information, See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 20
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS)
Alarm Module: Service and Repair Module - Passive Anti-Theft System (PATS)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION ^
Prior to removal of module, it is necessary to upload module configuration information to New
Generation STAR (NGS) Tester. This information needs to be downloaded in to the new module
once installed.
^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may
result.
2. Remove the LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the LH instrument panel insulator.
3. Remove the lower steering column cover.
1 Remove the screws.
2. Remove the lower steering column cover.
4. Remove the lower steering column cover reinforcement
1 Remove the screws.
2 Remove the lower steering column cover reinforcement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) >
Page 23
5. Remove the Passive Anti-Theft System (PATS) module and bracket.
1 Remove the bolts.
2 Disconnect the electrical connector.
INSTALLATION
1. To install,reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
^ Prior to starting the vehicle, check for PATS Diagnostic Trouble Codes (DTCs). Perform the
appropriate pinpoint test.
^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory.
Insert each key in the ignition and turn to RUN for automatic programming.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) >
Page 24
Alarm Module: Service and Repair Module - Passive Anti-Theft Transceiver
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Twist the tilt wheel handle and shank and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the lower steering column shroud.
3 Remove the upper steering column shroud.
NOTE: The steering wheel has been removed for clarity.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) >
Page 25
5. Remove LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the insulator.
6. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
7. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
8. Remove the transceiver assembly.
1 Remove the screw.
2 Release the transceiver over the rib on the lock cylinder housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) >
Page 26
NOTE: Only apply pressure below the key cylinder rib.
3 Disconnect the electrical connector locator and electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
^ No key replacement or re-initialization needs to occur with the removal or installation of a new
PATS transceiver.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation
Multifunction Electronic Control Module: Description and Operation
The multifunction modules consist of the following:
^ Air Suspension Control Module
^ Driver Door Module (DDM)
^ Lighting Control Module (LCM)
The air suspension control module is linked to its own Data Link Connector (DLC). The air
suspension control module controls the air suspension and the Electronic Variable Orifice (EVO)
steering.
The Driver Door Module (DDM) is connected on the International Standards Organization (ISO)
9141 communication network. The DDM controls many functions including power windows, power
door locks and remote keyless entry.
The Lighting Control Module (LCM) is connected on the ISO 9141 communication network. The
LCM controls both interior and exterior lighting, back lighting, the battery saver and warning
chimes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and Operation >
Page 30
Multifunction Electronic Control Module: Testing and Inspection
For Air Suspension concerns, See: Steering and Suspension/Suspension/Suspension Control (
Automatic - Electronic )
For Electronic Variable Orifice (EVO) Steering concerns,
For Warning Chime concerns, See: Instrument Panel, Gauges and Warning Indicators/Audible
Warning Device
For Lighting concerns, See: Lighting and Horns
For Power Window or Defroster concerns, See: Windows and Glass
For Power Door Lock concerns, See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Keyless Entry
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air
Suspension Module
Multifunction Electronic Control Module: Service and Repair Air Suspension Module
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Lower the instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Lower the instrument panel lower insulator.
3. Remove the instrument panel lower insulator.
1 Disconnect the power point electrical connector.
2 Remove the footwell lamp.
3 Remove the instrument panel lower insulator.
4. Remove the air suspension module.
1 Disconnect the electrical connectors.
2 Remove the air suspension module.
^ Release the spring clips to remove the module from the bracket.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air
Suspension Module > Page 33
Multifunction Electronic Control Module: Service and Repair Driver Door Module
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air
Suspension Module > Page 34
Multifunction Electronic Control Module: Service and Repair Lighting Control Module
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the LH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Disconnect the courtesy lamp.
3 Remove the LH instrument panel insulator.
3. Position the LCM aside.
1 Remove the locking tab.
2 Release the locking tab.
3 Position the LCM aside.
4. Remove the LCM.
1 Disconnect the electrical connectors.
2 Remove the LCM.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Air
Suspension Module > Page 35
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from New Generation STAR (NGS) Tester into the new module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 41
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 42
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 43
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 44
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 45
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 46
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47
Power Door Lock Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 54
Power Door Lock Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 56
Power Door Lock Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Diagrams > Page 59
Power Door Lock Control Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Power Mirror Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 64
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 65
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 66
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 67
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 68
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 69
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 70
Power Mirror Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 71
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 72
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 73
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 74
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 75
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 76
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 77
Power Mirror Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 78
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 79
Power Mirror Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 80
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 81
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Power Seat Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 86
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 87
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 88
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 89
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 90
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 91
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 92
Power Seat Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 93
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 94
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 95
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 96
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 97
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 98
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 99
Power Seat Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 100
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 101
Power Seat Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 102
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 103
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake
Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications
Anti-Lock Brake Control Module: Specifications
Retaining Screws .................................................................................................................................
................................................................. 1.8-2.8 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake
Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 108
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake
Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 109
Anti-Lock Brake Control Module: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Disconnect the anti-lock brake control module electrical connectors.
- Disconnect the control module electrical connector.
- Disconnect the pump motor electrical connector.
3. Remove the anti-lock brake control module.
1 Remove the screws.
2 Remove the module.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine
Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine
Spark Knock While Accelerating > Page 119
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine
Spark Knock While Accelerating > Page 120
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis
Drive/Propeller Shaft: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 126
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 127
For Dealerships without An Electronic Vibration Analyzer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 128
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 129
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 130
Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Drive/Propeller Shaft: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At
Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 135
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 136
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 01-1-14 > Jan > 01 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00
> PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 01-1-14 > Jan > 01 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00
> PCM - Engine Spark Knock While Accelerating > Page 146
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 01-1-14 > Jan > 01 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00
> PCM - Engine Spark Knock While Accelerating > Page 147
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > Customer Interest for
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > Customer Interest for
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 158
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > Customer Interest for
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 159
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating >
Page 165
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan
Control Module: > 99-18-1 > Sep > 99 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating >
Page 166
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations > Page 170
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 175
Compressor Clutch Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 176
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 181
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 182
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Blower Motor Speed Control
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Blower Motor Speed Control > Page 185
Control Module HVAC: Diagrams Electronic Climate Control Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Description and Operation > Blower Motor Speed Control
Control Module HVAC: Description and Operation Blower Motor Speed Control
The A/C blower motor speed control is located on the A/C evaporator housing, in the engine
compartment.
- The function of the A/C blower motor speed control is to convert low power signals from the
electronic automatic temperature control module to a high current, variable ground feed for the
blower motor.
- Blower motor speed is infinitely variable and is controlled by the electronic automatic temperature
control module software.
- A delay function provides a gradual increase or decrease in blower motor speed under all
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Description and Operation > Blower Motor Speed Control > Page 188
Control Module HVAC: Description and Operation Electronic Climate Control Module
The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel,
has the following features:
- a blower speed override control for manual input
- a vacuum fluorescent display for displaying set temperature, ambient temperature, function and
Diagnostic Trouble Codes (DTCs)
- an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes
(DTCs). These DTCs direct the technician to the inoperative component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Service and Repair > Blower Motor Speed Control
Control Module HVAC: Service and Repair Blower Motor Speed Control
REMOVAL
1. Disconnect the wire harness connector. 2. Drain the cooling system below the heater hoses.
3. Disconnect the heater hose.
4. Remove the screws and remove the blower motor speed control.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Service and Repair > Blower Motor Speed Control > Page 191
Control Module HVAC: Service and Repair Electronic Climate Control Module
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the screws and pull the Electronic Automatic Temperature Control (EATC) module from
the instrument panel.
4. Remove the EATC module.
- Remove the nuts and the vacuum harness.
- Disconnect the wire harness connectors and remove the EATC module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Service and Repair > Blower Motor Speed Control > Page 192
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Lighting Control Module
Audible Warning Device Control Module: Diagrams Lighting Control Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Lighting Control Module > Page 198
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Lighting Control Module > Page 199
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) >
Component Information > Description and Operation
Fuel Gauge Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 203
Fuel Gauge Module (CNG): Testing and Inspection
The Compressed Natural Gas fuel level indicator system is a function of the Natural Gas Vehicle
(NGV) module. For Testing and Inspection procedures,
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 204
Fuel Gauge Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 205
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 206
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications
Daytime Running Lamp Control Unit: Specifications
Daytime Running Lamps Module Bolt 27 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 211
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 212
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Remove the battery ground cable.
2. Remove the sight shield.
^ Twist the clips.
3. Remove the Daytime Running Lamps (DRL) module
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the DRL module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02
> Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: Customer Interest Turn Signals - Intermittent Rapid Flashing
Article No. 02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY
FORD: 1998-2002 CROWN VICTORIA
MERCURY: 1998-2002 GRAND MARQUIS
This article is being republished in its entirety to update the Service Procedure and to update the
parts required.
ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the
turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn
signal fast flash is not due to bulb outage, then verify good continuity at all ground screws.
ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the
latest engineering level as follows:
1 Disconnect the battery ground cable. For additional information refer to Workshop Manual
Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year.
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and
shaft. For additional information, refer to Section 310-02 of the Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02
> Turn Signals - Intermittent Rapid Flashing > Page 221
4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).
5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02
> Turn Signals - Intermittent Rapid Flashing > Page 222
13C788 42
OASIS CODES: 201000, 201100, 201200, 206000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7
> May > 02 > Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: All Technical Service Bulletins Turn Signals - Intermittent Rapid Flashing
Article No. 02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY
FORD: 1998-2002 CROWN VICTORIA
MERCURY: 1998-2002 GRAND MARQUIS
This article is being republished in its entirety to update the Service Procedure and to update the
parts required.
ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the
turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn
signal fast flash is not due to bulb outage, then verify good continuity at all ground screws.
ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the
latest engineering level as follows:
1 Disconnect the battery ground cable. For additional information refer to Workshop Manual
Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year.
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and
shaft. For additional information, refer to Section 310-02 of the Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7
> May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 228
4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).
5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7
> May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 229
13C788 42
OASIS CODES: 201000, 201100, 201200, 206000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Police Option Emergency Flasher Relay #1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 234
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 238
Horn Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 239
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 244
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 245
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 246
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 247
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 248
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 249
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 250
Interior Lighting Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 251
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 252
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 253
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 254
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 255
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 256
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 257
Interior Lighting Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 258
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 259
Interior Lighting Module: Electrical Diagrams
Diagram 58-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 260
Diagram 58-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 261
Diagram 58-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Lamp Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 266
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 267
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 268
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 269
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 270
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 271
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 272
Lamp Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 273
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 274
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 275
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 276
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 277
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 278
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 279
Lamp Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 280
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 281
Lamp Control Module: Electrical Diagrams
Diagram 58-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 282
Diagram 58-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 283
Diagram 58-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Page 284
Lamp Control Module: Description and Operation
The Lighting Control Module (LCM) eliminates the electronic interference and heat associated with
the thermoelectric devices used previously. The LCM is a microprocessor based module that
controls several vehicle subsystems. It responds to electrical signals from various switches,
sensors, and external modules.
LCM subsystem function include:
^ headlamps with autolamps
^ turn signal lamps/hazard flasher lamps
^ cornering lamps
^ parking lamps
^ courtesy lamps
^ demand lamps
^ battery saver
^ backlighting
^ interfacing with the driver door module via SCP for illuminated entry.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Page 285
Lamp Control Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the LH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Disconnect the courtesy lamp.
3 Remove the LH instrument panel insulator.
3. Position the LCM aside.
1 Remove the locking tab.
2 Release the locking tab.
3 Position the LCM aside.
4. Remove the LCM.
1 Disconnect the electrical connectors.
2 Remove the LCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Page 286
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from New Generation STAR (NGS) Tester into the new module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection > Page 291
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection > Page 295
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > High Current Relay Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > High Current Relay Center > Page 300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > High Current Relay Center > Page 301
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 308
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle
Article No. 99-4-3
03/08/99
REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V
VEHICLES ONLY
FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97
PROBE 1996-99 CONTOUR, ESCORT, TAURUS
LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN
CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR
LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER,
WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99
EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to update the affected vehicles and to include an
Application Chart for the affected vehicles.
ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket
service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain
reasonably priced, timely PCM programming services at dealerships. Ford has released an
out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are
reprogrammable to update calibration levels or to reprogram a common hardware type to a new
calibration in order to fill a service need without ordering a new PCM.
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Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 311
ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to
handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may
allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to
have modules updated to new calibrations through the Parts Department instead of ordering new
parts.
Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the
module. An aftermarket service center may bring a module to a dealership for a calibration update
or may request an updated calibration be installed to a new service part. The EPA regulations
require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash
Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a
calibration on a PCM out of the vehicle.
The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector.
The proper calibration must be downloaded to the Data Transfer Card through Service Bay
Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is
connected, follow the calibration download instructions displayed on the NGS screen.
The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling
1-800-ROTUNDA.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-26-3
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 203000, 206000, 290000, 690000, 698298
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Powertrain Control Module: Specifications
Powertrain Control Module Electrical Connector Bolt 4-7 Nm
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Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagrams > Diagram Information and Instructions > Page 317
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Powertrain Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Powertrain Control Module: Connector Views
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Powertrain Control Module: Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
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Service and Repair > Procedures
Powertrain Control Module: Procedures
Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit
(IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration
information specific to the vehicle.
The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire
contents. This is usually due to either an after production strategy change or the Vehicle
Identification (VID) area has been previously reprogrammed and has reached its limit. The VID
block area can be tailored to accommodate various hardware changes made to the vehicle since
production. The VID block is a section of memory within the IC which includes items such as
octane adjust, fuel octane, fuel type, tire size and axle ratio.
Programming a Replacement PCM
A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from
the original PCM before removing from the vehicle. Refer to the flash VID block update procedure.
After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM
config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary
to manually reprogram the VID block. The scan tool is used to perform this procedure and is done
through the "PCM Programming" selection as described by the flash EEPROM procedure below.
Follow screen instructions.
Flash EEPROM Procedure
When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The
Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto
the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash
cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM
Programming" or refer to the flash instruction manual provided in the kit. VID block information can
also be viewed and changed during this procedure.
Flash VID Block Procedure
When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS
flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select
"Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module
Installation". The screen will now display two selections. The first is for old PCM information to be
retrieved and stored within the NGS. The second is for restoring the new PCM with information
which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement
instruction sheet included with the Ford Service Function card. Next, either a transfer of data from
the old module to the new module or a manual update must be performed on the VID block. Follow
screen instructions or refer to the supplement instruction sheet included with the Ford Service
Function card. If the VID block has been reprogrammed previously, the scan tool will display a
message. This message will indicate the need to reflash the entire IC.
NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer.
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Powertrain Control Module: Reset Procedure
Purpose for Clearing Codes
Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning
contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset.
After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will
be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and
performance.
A Keep Alive Random Access Memory Reset is done as follows:
During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is
found in the Active Command Modes menu on the New Generation Star scan tool.
If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's
instruction manual.
If an error message is received or the scan tool does not support this function, disconnecting the
battery ground cable for a minimum of 5 minutes may be used as an alternative procedure.
Powertrain Control Module (PCM/KAM Reset)
All OBDII scan tools support the Powertrain Control Module (PCM) reset.
The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic
information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II
system monitors or components have been tested to satisfy a drive cycle, without any other faults
occurring.
The following events occur when a PCM reset is performed:
- Clears the number of Diagnostic Trouble Codes (DTCs).
- Clears the DTCs.
- Clears the freeze frame data.
- Clears diagnostic monitoring test results.
- Resets status of the OBD II system monitors.
- Sets DTC P1000.
NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the
CLEAR button. This function is performed only after retrieval of continuous DTCs.
New Generation Star and Generic Scan Tool
Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM
reset.
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Service and Repair > Procedures > Page 334
Powertrain Control Module: Removal and Replacement
Compressed Natural Gas Vehicle (NGV) Module
REMOVAL
WARNING
- DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
- IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Procedures > Page 335
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Procedures > Page 336
1. To install, reverse the removal procedure.
- Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Gasoline
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the screw and position the powertrain control module electrical connector out of the
way.
3. Remove the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Procedures > Page 337
4. Remove the powertrain control module cover.
5. Remove the three pin-type retainers and the under dash sight cover.
6. Remove the Powertrain Control Module (PCM).
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 341
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 342
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 343
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 344
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> PCM Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> PCM Power Relay > Page 350
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 355
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 356
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 357
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 358
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page
362
Fuel Valve Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page
363
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection >
PCM Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection >
PCM Power Relay > Page 369
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations
The ignition control module is integrated within the powertrain control module. It is not a separately
replaceable component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 374
Ignition Control Module: Description and Operation
PURPOSE
- The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM).
The ICM receives engine position and speed information from within the crankshaft position sensor
and desired spark advance information from the PCM.
OPERATION
- The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use
within The PCM.
- The PCM uses this information to determine which ignition coil to fire, calculating the turn
ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications
Air Bag Control Module: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Driver air bag module bolts ..................................................................................................................
........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts .......................
.............................................................................................................................................. 9 Nm (80
Lb-In) Air bag sensor bolts ..................................................................................................................
.................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts .......................
...................................................................................................................................................... 15
Nm (11 Lb-Ft) Forwarded Steering column nuts .................................................................................
.............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw
weld nut repair screw (8 mm)
....................................................................................................................... 12 Nm (9 Lb-Ft)
Grounding screw (6 mm) .....................................................................................................................
......................................................... 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 379
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 380
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 381
Air Bag Control Module: Service Precautions
WARNING:
- The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 382
Air Bag Control Module: Description and Operation
The air bag Electronic Crash Sensor (ECS) module performs the following functions:
- signals the inflators to deploy the air bags in the event of a deployable crash.
- monitors the air bag Supplemental Restraint System (SRS) for faults.
- illuminates the air bag indicator if a fault is detected.
- flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
- communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble
Codes (DTCs).
- signals the Lighting Control Module (LCM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the ECS and is not serviced separately.
The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the
RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will flash the two-digit
LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of
the key cycle. The ECS will also communicate the current and historical DTCs the DLC, using the
New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system
detects a fault condition, the ECS will signal the LCM to activate an audible chime. The chime is a
series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator
require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed first. After the fault has been corrected, the next highest priority fault will be
displayed.
The ECS includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors close. The backup power supply will deplete its stored energy approximately 1 minute
after the battery ground cable is disconnected.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 383
Air Bag Control Module: Service and Repair
REMOVAL
WARNING:
- The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the RH sill plate. 3. Position the carpet out of the way.
4. Remove the ECS.
1 Disconnect the ECS electrical connector locking clip.
2 Disconnect the ECS electrical connector.
3 Remove the three retaining screws.
4 Remove the ECS module and bracket.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 384
1. Follow the removal procedure in reverse order.
WARNING: The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- The tightening torque of the air bag electronic crash sensor (ECS) module bracket retaining
screws is critical for correct system operation.
NOTE: Make sure to tighten the retaining bolts to specification.
- A repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 389
The Starter Relay is located in the High Current Relay Center.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 390
Starter Relay: Description and Operation
The starter relay:
- is a mini ISO relay.
- switches power to the starter solenoid to engage the starter motor when it receives a START
signal from the ignition switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 391
Starter Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 392
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 393
Starter Relay: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Press the clips inward and open the relay junction box.
3. Remove the ISO starter relay.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations
Electronic Variable Orifice Steering Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations
> Page 399
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations
> Page 400
Electronic Variable Orifice Steering Module: Service and Repair
Removal
1. Lower the panel.
2. Remove the lamp from the panel and disconnect the wiring.
3. Remove the screws.
4. Disconnect the wiring and remove the control module.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 405
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 406
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Retaining Screws .................................................................................................................................
..................................... 2.3-3.3 Nm (20-29 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 410
Suspension Control Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 411
Suspension Control Module: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 412
Suspension Control Module: Description and Operation
A microprocessor controls the air suspension system. The microprocessor and its supporting
hardware are contained in the air suspension control module. The air suspension control module
responds to signals from various sensors in the vehicle to maintain the programmed ride height
while the vehicle is either moving or stopped. The air suspension control module accomplishes this
by opening and closing solenoid valves to control the amount of air in the air spring(s). The air
suspension control module turns on the compressor by applying voltage through the compressor
relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the
vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs
from the air suspension height sensor(s).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 413
Suspension Control Module: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Pull out the lower instrument panel insulator.
1 Remove the pushpins.
2 Pull out the lower instrument panel insulator.
4. Remove the lower instrument panel insulator.
1 Disconnect the power point.
2 Disconnect the courtesy lamp.
3 Remove the lower instrument panel insulator.
5. Remove the rear air suspension control module.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the rear air suspension control module.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 414
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 419
Heated Glass Element Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 420
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
One Touch Window Down Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 425
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 426
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 427
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 428
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 429
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 430
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 431
One Touch Window Down Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 432
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 433
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 434
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 435
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 436
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 437
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 438
One Touch Window Down Module: Connector Views
Driver Door Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 439
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 440
One Touch Window Down Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 441
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 442
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 443
One Touch Window Down Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 448
Wiper Control Module: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
2. Remove the tunnel brace trim cover.
1 Remove pin-type retainers.
2 Remove the tunnel brace trim cover.
3. Position the instrument panel ash receptacle aside.
1 Remove the screws.
2 Position the instrument panel ash receptacle aside.
4. Remove the instrument panel ash receptacle assembly.
1 Disconnect the electrical connector.
2 Remove the instrument panel ash receptacle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 449
5. Remove the windshield wiper control module.
1 Remove the screw.
2 Disconnect the electrical connector.
3 Remove the windshield wiper control module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Lock Switch >
Component Information > Description and Operation
Fuel Door Lock Switch: Description and Operation
The fuel filler door lock switch:
- actuates a solenoid integral to the fuel filler door latch to release the fuel filler door.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated
Replacement Part
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement
Part
Article No. 01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES
1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION
LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD
MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree
Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical
switches will be available as a service replacement.
ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury
switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate
model year Workshop Manual as needed.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 201000, 201200
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 464
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch
Power Door Lock Switch: Testing and Inspection LF Door Lock Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch > Page 467
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch > Page 468
Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch > Page 469
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Page 470
Power Door Lock Switch: Service and Repair
REMOVAL
1. Remove the window regulator switch plate.
2. Remove the screws.
3. Disconnect the connector.
4. Remove the door lock switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 474
Power Mirror Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 475
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 476
Power Mirror Switch: Service and Repair
REMOVAL
1. Remove the window regulator switch plate from the front door trim panel.
CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or
damage to the front door trim panel may occur.
2. Release the tabs.
3. Remove the exterior rear view mirror control switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Driver's Seat Control Switch
Power Seat Switch: Diagrams Driver's Seat Control Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Driver's Seat Control Switch > Page 481
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch
Power Seat Switch: Testing and Inspection Driver's Seat Control Switch
Driver Seat Control Switch (All Others)
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 484
Schematic
Driver Seat Control Switch (Base and Police)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 485
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 486
Terminals
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 487
Power Seat Switch: Testing and Inspection Passenger Seat Control Switch
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 488
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 489
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Front Seat Occupied Switch
Power Seat Switch: Service and Repair Front Seat Occupied Switch
REMOVAL
1. Disconnect the battery. 2. Remove the seat. 3. Remove the seat track.
4. Disconnect the connector.
5. Slide the retainers outboard.
6. Remove the switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Front Seat Occupied Switch > Page 492
Power Seat Switch: Service and Repair Lumbar Seat Control Switch
REMOVAL
1. Disconnect the battery. 2. Remove the seat.
3. Remove the cover.
4. Remove the screws.
5. Disconnect the connector.
6. Disconnect the vacuum tubes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Front Seat Occupied Switch > Page 493
NOTE: Mark the tubes before disconnecting.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Front Seat Occupied Switch > Page 494
Power Seat Switch: Service and Repair Seat Regulator Control Switch
REMOVAL
1. Disconnect the battery. 2. Remove the front door trim panel.
3. Remove the seat regulator control switch.
1 Remove the screws.
2 Remove the switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Measured using Rotunda EEC-IV 60-Pin Breakout Box
Front and Rear 800-1400 ohms
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications > Page 500
Wheel Speed Sensor: Mechanical Specifications
Retaining Bolts Front 36-53 in.lb
Rear 14-19 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front
Wheel Speed Sensor: Service and Repair Front
Removal
1. Disconnect the front anti-lock brake sensor electrical connector. 2. Raise and support the
vehicle.
3. Remove the routing clips.
4. Remove the front anti-lock brake sensor.
1 Remove the bolt.
2 Remove the sensor.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 503
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 504
Wheel Speed Sensor: Service and Repair Rear
Removal
1. Remove rear seat bottom.
2. Disconnect the rear anti-lock brake sensor electrical connector.
3. Push the sensor harness grommet through the passenger compartment floor. 4. Raise and
support the vehicle.
5. Disconnect the routing clips.
6. Remove the rear anti-lock brake sensor.
1 Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 505
2 Remove the sensor.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description
and Operation
Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation
NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor
provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant
Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling
fans.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 517
Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component
Information > Service and Repair
Engine Coolant Temperature Sender: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Partially drain the engine cooling system.
2. Remove the water temperature indicator sender unit.
1 Disconnect the electrical connector.
2 Remove the water temperature indicator sender unit.
Installation
1. Install the water temperature indicator sender unit.
1 Install the water temperature indicator sender unit.
2 Connect the electrical connector.
2. Fill the engine cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake
Switch (Cruise Control)] > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake
Switch (Cruise Control)] > Component Information > Diagrams > Page 525
Deactivator Switch: Adjustments
NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake
Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch
Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the lower insulator.
1 Remove the push pins.
2 Disconnect the interior lamp.
3 Remove the lower insulator.
3. Disconnect the Brake Pedal Position (BPP) switch.
4. Remove the BPP switch.
1 Remove the cotter pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake
Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 528
2 Remove the sleeve.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake
Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 529
Deactivator Switch: Service and Repair Deactivator Switch
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the deactivator switch.
1 Disconnect the electrical connector.
2 Rotate counterclockwise and remove the deactivator switch.
INSTALLATION
1. Pull the plunger out to its full travel. 2. Fully depress the brake pedal.
3. Install the deactivator switch.
1 Position the deactivator switch in the bracket and rotate clockwise.
2 Connect the electrical connector.
4. Slowly release the brake pedal. 5. Connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn its strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair
Cruise Control Switch: Service and Repair
REMOVAL
1. Remove the steering wheel.
2. Remove the steering wheel cover screws.
3. Remove the steering wheel cover.
1 Position the steering wheel cover aside.
2 Disconnect the electrical connector and wire harness from the steering wheel cover.
3 Remove the steering wheel cover.
4. Remove the speed control actuator switches.
1 Push the speed control actuator switches out towards the face of the steering wheel.
2 Position the speed control actuator switches through the steering wheel openings and remove.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Engine Oil Pressure Switch <--> [Oil
Pressure Sender] > Component Information > Locations
Engine Oil Pressure Switch: Locations
1. Oil Pressure Sensor
2. Oil Pressure Sensor Connector
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Engine Oil Pressure Switch <--> [Oil
Pressure Sender] > Component Information > Locations > Page 537
Engine Oil Pressure Switch: Service and Repair
Removal
1. Remove the oil pressure sensor oil pressure sensor:
1 Disconnect the wire.
2 Remove the oil pressure sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Air Temperature Sensor <-->
[Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation
Ambient Air Temperature Sensor: Description and Operation
The A/C ambient air temperature sensor and bracket:
- is located in front of the A/C condenser core near the center of the vehicle.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the electronic automatic temperature control assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Air Temperature Sensor <-->
[Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation > Page 542
Ambient Air Temperature Sensor: Service and Repair
REMOVAL
1. Remove the radiator upper sight shield.
2. Disconnect the wire harness connector.
3. Remove the A/C ambient air temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > In-Car Temperature Sensor <-->
[Cabin Temperature Sensor / Switch] > Component Information > Description and Operation
In-Car Temperature Sensor: Description and Operation
The in-car temperature sensor operates in the following manner:
- A thermistor in the in-car temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the A/C
evaporator housing and the in-car temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the A/C evaporator
housing air stream to create a suction in the in-car temperature sensor.
- The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > In-Car Temperature Sensor <-->
[Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 546
In-Car Temperature Sensor: Service and Repair
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the screws and pull the control assembly away from the instrument panel.
4. Remove the screws and position the in-car temperature sensor to access the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > In-Car Temperature Sensor <-->
[Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 547
5. Disconnect the connector.
6. Disconnect the hose and remove the in-car temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications > Mechanical Specifications
Refrigerant Pressure Sensor / Switch: Mechanical Specifications
A/C Pressure Cut-off Switch
.....................................................................................................................................................
6.8-13.6 N.m (61-120 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications > Mechanical Specifications > Page 552
Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications
A/C Cycling Switch
Close ...................................................................................................................................................
.................................... 276-324 kPa (40-47 psi) Open .......................................................................
................................................................................................................ 152-193 kPa (22-28 psi)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch
The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the A/C
compressor to condenser discharge line.
- A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch
contacts open, disengaging the A/C compressor.
- When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow
operation of the A/C compressor.
- It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 555
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction
accumulator/driver.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction or low side pressure to control the operation of the A/C cycling switch.
- The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi).
- The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi).
- When the A/C cycling switch contacts close, the A/C clutch field coil is energized.
- When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of airflow.
- It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Service and Repair > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch
REMOVAL
1. Disconnect the wire harness connector.
2. Remove the A/C cycling switch.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 558
Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch
REMOVAL
1. Disconnect the wire harness connector.
2. Remove the A/C pressure cut-off switch.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Description and Operation
Solar Sensor: Description and Operation
The A/C sunload sensor:
- is located on the top RH side of the instrument panel above the glove compartment.
- contains a photovoltaic diode that is sensitive to light.
- has some unspecified resistance across the terminals depending upon the amount of light
reaching the photovoltaic diode; therefore the only test that can be performed is for an internal
short circuit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Description and Operation > Page 562
Solar Sensor: Service and Repair
REMOVAL
1. Remove the instrument panel upper finish panel.
2. Disconnect the wire harness connector.
3. Remove the A/C sunload sensor from the instrument panel upper finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Warning Switch <-->
[Key Reminder Switch] > Component Information > Service and Repair
Key Warning Switch: Service and Repair
REMOVAL
1. Remove the ignition lock cylinder.
1 Insert the key into the ignition key and turn to the RUN position.
2 Insert a punch in the access hole of the steering column and press the release tab while pulling
out the ignition switch lock cylinder.
2. Remove the key-in-ignition warning switch.
1 Release the clip.
2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure
^ Verify ignition lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Diagrams > Page 571
Ambient Light Sensor: Service and Repair
REMOVAL
1. Unclip the instrument panel upper finish panel.
2. Disconnect the light sensor amplifier electrical connector.
CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel
to expose the connector without stretching the wiring.
3. Unclip the light sensor amplifier.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 >
Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 >
Stoplamps/Shift Interlock - Inoperative > Page 583
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 02-13-6 >
Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 02-13-6 >
Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 589
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 590
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 591
Brake Light Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the LH instrument panel insulator. ^
Disconnect the courtesy lamp.
3. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
4. Remove the BPP switch.
1 Remove the self-locking pin.
2 Remove the (A) BPP switch from the (B) brake master cylinder push rod.
3 Remove the brake master cylinder push rod spacer.
4 Remove the brake master cylinder push rod bushing.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Hazard Warning Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 595
Hazard Warning Switch: Description and Operation
PRINCIPLES OF OPERATION
The hazard flasher switch (part of the multifunction switch) is located on the top of the steering
column, forward of the steering wheel. ^
The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the
switch top.
^ The switch should produce an audible click when it toggles from one state to another.
^ The switch should extend markedly further above the column when the switch is ON than it does
when it is OFF.
When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the
two turn indicators in the instrument cluster will flash simultaneously.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Component Test
Hazard Warning Switch: Testing and Inspection Component Test
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Component Test > Page 598
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Component Test > Page 599
Hazard Warning Switch: Testing and Inspection Operational Test
The hazard flasher switch (part of the multifunction switch) is located on the top of the steering
column, forward of the steering wheel.
- The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the
switch top.
- The switch should produce an audible click when it toggles from one state to another.
- The switch should extend markedly further above the column when the switch is ON than it does
when it is OFF.
When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the
two turn indicators in the instrument cluster will flash simultaneously.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 600
Hazard Warning Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 601
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 602
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams
Headlamp Dimmer Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 606
Headlamp Dimmer Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 607
Headlamp Dimmer Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 608
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 609
Headlamp Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 610
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 611
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams
Main Light Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 615
Main Light Switch: Description and Operation
The headlamp switch is a multi-position switch.
^ The positions include OFF, PARK, and HEAD.
^ With the headlamp switch in the PARK position (first detent), a signal is supplied to the LCM
which powers the front parking lamps, the tail lamps, the side marker lamps, and the license lamp.
^ With the headlamp switch in the HEAD position, power is supplied to the headlamps through the
LCM and the multifunction switch.
^ The panel dim switch (part of the headlamp switch) is located above the headlamp switch. The
panel dim switch operates only with the parking lamps or headlamps on.
^ When the panel dim switch is held in the up position, the instrument panel lighting will
progressively brighten.
^ When the panel dim switch is held in the down position, the instrument panel lighting will
progressively dim.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 616
Main Light Switch: Testing and Inspection
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 617
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 618
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 619
Main Light Switch: Service and Repair
REMOVAL
1. Remove the instrument panel cluster finish panel.
2. Remove the headlamp switch.
^ Unclip the switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Service and Repair
Horn Switch: Service and Repair
REMOVAL AND INSTALLATION
NOTE: The horn switch is integral to the driver side air bag module and cannot be replaced
separately.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams
Multifunction Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 626
Multifunction Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 627
Multifunction Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 628
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 629
Multifunction Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 630
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 631
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch
> Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement
Part
Article No. 01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES
1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION
LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD
MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree
Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical
switches will be available as a service replacement.
ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury
switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate
model year Workshop Manual as needed.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 201000, 201200
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 646
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 647
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
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> Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
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voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
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1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Page 655
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
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> Technical Service Bulletins > Page 656
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Page 657
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
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> Technical Service Bulletins > Page 658
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
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662
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Page 669
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
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Page 670
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
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Page 671
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
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Page 675
Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Fuel Tank Pressure Sensor: Specifications
Fuel Tank Pressure Sensor 55 Nm
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Page 679
Fuel Tank Pressure Sensor: Service and Repair
NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs.
REMOVAL
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the NGV fuel tank pressure sensor.
1 Disconnect the NGV fuel tank pressure sensor electrical connector.
2 Remove the NGV fuel tank pressure sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy.
^ Replace the NGV fuel tank pressure sensor O-ring seal.
^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil
XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to
help seal and ease the installation.
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
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Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Emissions/Engine Controls - Driveability Diagnosis > Page 688
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Emissions/Engine Controls - Driveability Diagnosis > Page 689
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Oxygen Sensor: Specifications
Heated Oxygen Sensor - Front (HO2S) 36-46 Nm
Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm
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H02S Location
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Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 715
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 716
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 717
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 718
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 719
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front
Oxygen Sensor: Service and Repair Front
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S).
3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and
support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front >
Page 722
5. Remove the front heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford
specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front >
Page 723
Oxygen Sensor: Service and Repair Rear
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S).
4. Remove the rear heated oxygen sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front >
Page 724
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford
specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 728
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 729
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 730
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 737
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 738
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 739
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 740
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 746
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 747
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 748
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 749
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 750
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 751
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 752
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 753
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 754
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 755
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 756
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 757
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 758
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 763
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 764
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 765
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 775
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 776
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 782
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 783
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 784
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 785
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 786
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 787
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications
Fuel Temperature Sensor: Specifications
Fuel Tank Temperature Sensor 40 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair >
Fuel Tank Temperature (Upper) Sensor
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor
REMOVAL
NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.1.
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the upper NGV fuel tank temperature sensor.
1 Disconnect the electrical connector.
2 Remove the fuel tank temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair >
Fuel Tank Temperature (Upper) Sensor > Page 793
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor
REMOVAL
NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.2.
1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle.
3. Remove the lower NGV fuel tank shield upper nuts.
4. Remove the lower NGV fuel tank shield.
1 Remove the nuts.
2 Remove the lower NGV fuel tank shield.
5. Remove the lower NGV fuel tank temperature sensor.
1 Disconnect the lower NGV fuel tank temperature sensor electrical connector.
2 Remove the lower NGV fuel tank temperature sensor.
INSTALLATION
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair >
Fuel Tank Temperature (Upper) Sensor > Page 794
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy
^ Replace the lower NGV fuel tank temperature sensor O-ring seal.
^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30
engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to
installation, to help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 803
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 804
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 805
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 806
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 807
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 808
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 809
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 810
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 811
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 812
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels
Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 827
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 828
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 829
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 830
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 831
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 832
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 833
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 834
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 835
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Inertia Fuel Shutoff Switch: > 02-11-2 > Jun > 02 > Recalls for Inertia Fuel Shutoff
Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 836
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 842
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 843
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 844
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 845
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 846
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 847
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 848
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 849
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 850
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Pad: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
> Page 851
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Technical Service Bulletins > Customer Interest for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on
Wheels
Brake Pad: Customer Interest Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive
Brake Dust on Wheels
Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Technical Service Bulletins > Page 864
Brake Pad: Specifications
Front Rear
Thickness, Min. 0.039 in 0.039 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Service and Repair > Front
Brake Pad: Service and Repair Front
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Remove brake master cylinder filler cap. Check brake fluid level in brake master cylinder reservoir.
Remove fluid until brake master cylinder reservoir is half full.
2. Raise and support the vehicle. 3. Remove the wheel and tire assembly.
4. CAUTION: Replace the pad if worn to or past the specified thickness above the metal backing
plate or rivets. Replace the pads in
complete axle sets.
Inspect the pads for wear and contamination.
5. CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the pistons and
boots.
CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose.
Provide a suitable support.
Remove the disc brake caliper. 1
Remove two front disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
6. Remove the disc brake pad anti-rattle clip.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Service and Repair > Front > Page 867
7. Measure the brake disc thickness.
- Replace the brake disc if not within specification.
8. Inspect the disc brake caliper.
- If leaks or damaged boots are found, disassembly is required.
9. Remove the pads and stainless steel slippers.
1 Remove the pads and verify thickness.
2 Remove the front disc brake caliper anchor plate stainless steel slippers and discard.
10. Inspect the front disc brake anchor plate assembly.
- Check the guide pin boots for damage.
- Check the guide pins for binding and damage.
- Replace worn or damaged pins.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Service and Repair > Front > Page 868
Installation
1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining
material. Do not install contaminated
pads.
NOTE: Replace all hardware supplied with pad kit.
Install the pads. 1
Install the new front disc brake caliper anchor plate stainless steel slippers.
2 Install the pads.
2. NOTE: Use a wood block or used pad to protect pistons and boots.
Compress the caliper pistons.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Service and Repair > Front > Page 869
3. Install the disc brake pad anti-rattle clip.
4. CAUTION: Use care not to damage the bleeder screw or brake disc shield.
Install the disc brake caliper. 1
Install the disc brake caliper.
2 Install the disc brake caliper bolts.
5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Fill the brake master cylinder
reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3
fluid meeting
Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford
specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap.
8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Inspect brake operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Service and Repair > Front > Page 870
Brake Pad: Service and Repair Rear
Removal
1. Inspect the brake pads for wear or contamination. Install new if worn to or past specification.
2. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure.
Remove the rear disc brake caliper.
3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads.
Remove the brake pads by pushing inward and rotating the pad up.
4. NOTE: Use a block of wood or used pad to protect the piston and boots.
Retract the caliper piston into the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Service and Repair > Front > Page 871
5. Make sure the slippers are clean and in good condition.
Installation
1. CAUTION: Install the brake pads in full axle sets. Do not replace worn brake pads on only one
side of vehicle.
Install the brake pads.
2. Install the rear disc brake caliper. 3. Verify correct brake operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Component Information
> Page 872
Brake Pad: Specifications
Front Rear
Thickness, Min. 0.039 in 0.039 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 880
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 884
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 885
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 886
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available
Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 892
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 893
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 894
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 895
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 896
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 897
Ignition Switch Lock Cylinder: Specifications
Lock Cylinder Housing Screws ............................................................................................................
.................................................... 22 Nm (16 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional
Ignition Switch Lock Cylinder: Service and Repair Functional
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional > Page 900
Ignition Switch Lock Cylinder: Service and Repair Non-Functional
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional > Page 901
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the steering column lock housing bearing and steering column lock gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
1. Install the steering column lock gear and bearing.
^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification
ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing
bearing.
^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three
o'clock position. Rotate it counterclockwise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional > Page 902
2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install
the steering wheel.
4. Install the ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 906
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Specifications
Impact Sensor: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Specifications > Page 911
Impact Sensor: Service Precautions
WARNING:
- Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag
Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Specifications > Page 912
Impact Sensor: Service and Repair
REMOVAL
WARNING:
- Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag
Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator upper
sight shield.
3. Remove the air bag sensor.
1 Disconnect the air bag sensor electrical connector.
2 Remove the three screws.
3 Remove the air bag sensor.
INSTALLATION
1. Follow the removal procedure in reverse order.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Specifications > Page 913
auxiliary batteries and power supplies (if equipped).
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available
Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 920
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 921
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 922
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 923
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 924
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 925
Ignition Switch Lock Cylinder: Specifications
Lock Cylinder Housing Screws ............................................................................................................
.................................................... 22 Nm (16 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional
Ignition Switch Lock Cylinder: Service and Repair Functional
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 928
Ignition Switch Lock Cylinder: Service and Repair Non-Functional
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 929
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the steering column lock housing bearing and steering column lock gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
1. Install the steering column lock gear and bearing.
^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification
ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing
bearing.
^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three
o'clock position. Rotate it counterclockwise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 930
2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install
the steering wheel.
4. Install the ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 939
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 940
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 941
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications
Ride Height Sensor: Specifications
Mounting Bracket To Lateral Arm
...........................................................................................................................................................
14 Nm (10 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 946
Ride Height Sensor: Description and Operation
The air suspension height sensor sends signals to the air suspension control module. There are
three possible conditions that the air suspension control module interprets from the signals of the
air suspension height sensors. The conditions are trim height, below trim height, or above trim
height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 947
Ride Height Sensor: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support
the vehicle.
4. Disconnect the air suspension height sensor electrical connector.
5. Remove the air suspension height sensor.
^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball
studs.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 951
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 952
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 953
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation
Suspension Mode Switch: Description and Operation
CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is
hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of
the system and possible damage to the air suspension system components.
The air suspension switch provides a signal to the air suspension control module in the ON position
to activate the system to maintain the programmed vehicle height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation > Page 957
Suspension Mode Switch: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Peel back the luggage compartment trim.
1 Remove the pushpins.
2 Peel back the luggage compartment trim.
4. Remove the air suspension switch.
1 From behind the quarter panel reinforcement, depress the clips.
2 Remove the air suspension switch.
5. Disconnect the electrical connector.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift
Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift
Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 968
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 974
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 978
Transmission Mode Switch: Description and Operation
The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of
the transmission control selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF
will illuminate on the transmission control selector lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 979
Transmission Mode Switch: Service and Repair
TRANSMISSION MODE SWITCH
Removal
1. Remove the Transmission Control (TC) switch.
1. Remove the TC switch cover. 2. Remove the TC switch.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 983
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 984
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 985
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 986
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 990
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch > Page 999
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch > Page 1000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch > Page 1001
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Page 1002
Power Window Switch: Description and Operation
PRINCIPLES OF OPERATION
The driver power window one touch down operation is controlled by the Driver Door Module
(DDM), if equipped with remote keyless entry, or the one touch down module if not equipped with
remote keyless entry. The one touch down operation is requested of the module by momentarily
pressing the driver window down switch for 32 ms to 480 ms. The module uses the initial voltage
input from the down switch to begin one touch down operation. If the voltage input was less than
480 ms, the module will maintain the voltage supply to the motor down circuit. Circuit breaker 14
(20 A) supplies the power to the module for this operation. The module will maintain the operation
until: seven seconds expire.
- the module detects motor stalled by monitoring the current draw.
- a voltage input is received by the module on either the up or down switch circuits.
The ground for one touch down operation does not pass through the module. The ground is
supplied through the driver window switch as with normal operation. If the module continues to
detect voltage on the down circuit for more than 480 ms after initial activation, the module will not
affect operation. The down circuit through the module is a direct connection to the motor in its
normal state. This allows the driver window switch to control the motor for normal operation.
The passenger window motors are hardwired directly to the window regulator control switches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch
Power Window Switch: Testing and Inspection LR Window Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1005
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1006
Power Window Switch: Testing and Inspection Master Power Window Switch
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1007
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1008
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1009
Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1010
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 1011
Power Window Switch: Testing and Inspection Right Rear Power Window Switch
Component Testing Procedure
Terminals
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 1012
Power Window Switch: Service and Repair
REMOVAL
1. Remove the switch bezel.
2. Remove the screws.
3. Disconnect the connector.
4. Remove the master window regulator control switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation
Windshield Washer Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 1017
Windshield Washer Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 1018
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 1019
Windshield Washer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 1020
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 1021
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Description and Operation
Wiper Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Description and Operation > Page 1025
Wiper Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Description and Operation > Page 1026
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Description and Operation > Page 1027
Wiper Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Description and Operation > Page 1028
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Description and Operation > Page 1029
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive
Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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Noise/Vibration/Harshness Procedure > Page 1036
^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Noise/Vibration/Harshness Procedure > Page 1037
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Noise/Vibration/Harshness Procedure > Page 1038
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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Noise/Vibration/Harshness Procedure > Page 1039
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Noise/Vibration/Harshness Procedure > Page 1040
Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Noise/Vibration/Harshness Procedure > Page 1041
Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
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Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
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Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
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^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
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^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
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Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
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CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
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3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
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Alignment: Specifications
NOTE: All specifications are given for a vehicle at curb load.
CAMBER:
Nominal ...............................................................................................................................................
..................................................................... -0.50° Tolerance ............................................................
.....................................................................................................................................................
±0.75° Difference/Split (Left Minus Right)
Nominal ...............................................................................................................................................
................................................................ 0.00° Tolerance ..................................................................
......................................................................................................................................... ±0.75°
CASTER:
Nominal ...............................................................................................................................................
.................................................................... +5.50° Tolerance ............................................................
.....................................................................................................................................................
±0.75° Difference/Split (Left Minus Right)
Nominal ...............................................................................................................................................
................................................................ +0.5° Tolerance ..................................................................
......................................................................................................................................... ±0.75°
TOTAL TOE [a]
Degree:
Nominal ...............................................................................................................................................
............................................................. -0.125° Tolerance ..................................................................
......................................................................................................................................... ±0.25°
CLEAR VISION [b]:
Nominal ...............................................................................................................................................
....................................................................... -2.0° Tolerance ............................................................
.......................................................................................................................................................
±3.0°
RIDE HEIGHT
Base
Front ....................................................................................................................................................
........................ 29.6 ±12.7 mm (1.2 ±0.5 inch) Rear ...........................................................................
................................................................................................ 138.0 ±7.60 mm (5.4 ±0.3 inch)
Air Suspension
Front ....................................................................................................................................................
........................ 27.4 ±12.7 mm (1.1 ±0.5 inch) Rear ...........................................................................
.................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch)
With Handling package
Front ....................................................................................................................................................
........................ 26.0 ±12.7 mm (1.0 ±0.5 inch) Rear ...........................................................................
.................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch)
Police/NGV
Front ....................................................................................................................................................
........................ 26.4 ±12.7 mm (1.0 ±0.5 inch) Rear ...........................................................................
.................................................................................................. 132.3 ±7.6 mm (5.2 ±0.3 inch)
VEHICLE LEAN (Side to Side Height Difference)
Front ....................................................................................................................................................
................................................ 12.7 mm (0.5 inch) Rear .....................................................................
................................................................................................................................ 12.7 mm (0.5
inch)
[a] Positive value is toe-in, negative value is toe-out. [b] Position of steering wheel spoke to
horizontal. Negative value specification is counterclockwise.
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Alignment: Description and Operation
Camber and caster are adjusted by means of two adjustment cams located on each upper control
arm. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve.
CAMBER
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
CASTER
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
TOE
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Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
RIDE HEIGHT
Front Ride Height Measurement
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Rear Ride Height Measurement
On vehicles equipped with an air suspension system, the vehicle ride height can only be measured
accurately after the accurate trim test has been executed using a NGS tester.
Wheel Track
WHEEL TRACK
Refer to image provided.
DOGTRACKING
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Dogtracking
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
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.
SHIMMY
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
NIBBLE
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces and observed by the driver as small rotational oscillations of the steering wheel.
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 the steering correction is completed.
DRIFT/PULL
Pull is 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 hands off the steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road crown).
POOR GROOVE FEEL
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^
Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the
steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the
self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber
Alignment: Service and Repair Caster and Camber
1. Loosen the nuts.
2. To adjust the camber, rotate the adjustment cam.
^ To increase camber, rotate the adjustment cam clockwise.
^ To decrease camber, rotate the adjustment cam counterclockwise.
3. To adjust the caster, rotate the adjustment cam.
^ To increase the caster, rotate the adjustment cam clockwise.
^ To decrease the caster, rotate the adjustment cam counterclockwise.
4. Hold each cam and tighten the nuts. 5. Recheck the camber and caster. Follow the
manufacturer's instructions. Readjust the camber and caster as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber >
Page 1137
Alignment: Service and Repair Toe
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Check the toe settings. Follow the manufacturer's instructions.
4. Loosen the nuts.
^ Clean-and lubricate the steering linkage and tie rod end threads.
5. Rotate the adjusting sleeves to obtain the correct toe setting.
6. Position the adjusting sleeve clamps within the horizontal and vertical limits shown. Tighten the
nuts. 7. Recheck the toe settings. Follow the manufacturer's instructions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Pressure
Fuel Pressure: Specifications Fuel Pressure
Fuel Pressure
Fuel Rail Pressure 105 - 130 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Pressure > Page 1143
Fuel Pressure: Specifications Volume
Flow .....................................................................................................................................................
................................................................. 160 lbs/hr
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications Idle Speed
Idle Speed
Hot Idle 790-815 rpm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
REMOVAL
1. On gasoline vehicles, remove the engine appearance cover.
^ Loosen the retainer.
^ Remove the cover.
2. Remove the idle air control valve inlet tube.
3. Remove the crankcase ventilation hose.
4. Loosen the clamps and remove the air cleaner outlet tube.
NOTE: Gasoline shown, natural gas similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1151
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
1. Release the metal clips.
2. Lift the cover.
3. Remove the Air Cleaner (ACL) element.
INSTALLATION
1. To install,reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1160
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1161
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1162
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1163
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1164
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1165
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1166
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1167
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1168
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1169
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1170
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1171
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1172
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1173
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1174
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1175
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1176
6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1177
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1178
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1179
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1180
8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1181
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap > Page 1193
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1194
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
............................................................... AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1195
Spark Plug: Description and Operation
The spark plugs:
^ change a high voltage pulse into a spark which ignites the fuel and air mixture.
^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1196
Spark Plug: Service and Repair
REMOVAL
1. Remove the ignition coil.
2. Remove the spark plugs.
NOTE: Use compressed air to remove any debris from the spark plug well before removing the
spark plugs.
3. Inspect the spark plugs for a gap bridged.
^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
4. Inspect for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1197
5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips,
exposed shell surfaces and electrodes. This is caused
by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive
idling. ^
Clean the spark plug.
6. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
7. Inspect for pre-ignition,
^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the
insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of
fuel or the installation of a heli-coil insert in place of the spark plug threads.
^ Install a new spark plug.
8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown
spots with bluish-burnt appearance of
electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs,
spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1198
^ Install a new spark plug.
9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or
blisters. These are caused by sudden acceleration.
^ Clean the spark plug.
10. Adjust the spark plug gap as required.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1202
Compression Check: Testing and Inspection
Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the
battery is properly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons
in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating improperly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1203
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications
Drive Belt: Specifications
Drive Belt Tension See Note
Newly Installed-Refers To The Condition Of The NEW Drive
Belt Before The Engine Has Made No More Than One Revolution
And Before The Belt Has Had A Chance To Stretch Or Seat
Into The Pulley Grooves
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1210
Drive Belt: Diagrams
Part 1 Of 2
Part 2 Of 2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1211
Drive Belt: Service and Repair
Removal
1. Rotate the tensioner clockwise and remove the drive belt.
Installation
1. CAUTION: Incorrect drive belt installation will cause drive belt failure.
NOTE: Make sure the drive belt is correctly installed on each pulley.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component
Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
REMOVAL
1. On gasoline vehicles, remove the engine appearance cover.
^ Loosen the retainer.
^ Remove the cover.
2. Remove the idle air control valve inlet tube.
3. Remove the crankcase ventilation hose.
4. Loosen the clamps and remove the air cleaner outlet tube.
NOTE: Gasoline shown, natural gas similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component
Information > Service and Repair > Page 1217
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair
Air Filter Element: Service and Repair
REMOVAL
1. Release the metal clips.
2. Lift the cover.
3. Remove the Air Cleaner (ACL) element.
INSTALLATION
1. To install,reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
This model is not equipped with a cabin air filter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1229
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1230
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1231
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1232
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1233
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1234
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1235
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1236
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1237
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1238
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1239
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1240
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1241
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1242
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1243
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1244
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1245
6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1246
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1247
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1248
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1249
8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Special Tools Used While Performing Procedures > Page 1250
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1260
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1261
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
1267
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
1268
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Page 1269
Heater Hose: Service and Repair
REMOVAL
1. Drain the radiator.
2. Remove the heater hoses from the heater core.
3. Remove the heater hoses from the engine.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or
equivalent meeting Ford specification ESF-M99B112-A.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
Hose/Line HVAC: Description and Operation
REFRIGERANT LINES
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C
evaporator core orifice.
The A/C compressor to condenser discharge line contains high pressure refrigerant gas. It has the
following features: an integral non-serviceable muffler
- a fitting used to mount the A/C pressure cut-off switch. (A long-travel Schrader-type valve stem
core is installed in the fitting so that the A/C pressure cut-off switch can be removed without
discharging the A/C system.)
- a fitting used to mount a serviceable high-pressure A/C charge port valve
The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the
following features: The upstream side contains low pressure refrigerant gas.
- The downstream side contains high pressure refrigerant gas and a port to mount the A/C
compressor pressure relief valve.
The accumulator to compressor tube has a fitting used to mount the A/C cycling switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch
can be removed without discharging the A/C system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C
Discharge Hose/Line
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line
REMOVAL
1. Disconnect the battery ground cable. 2. Recover the refrigerant.
3. Disconnect the A/C pressure cut-off switch wire harness connector.
4. Remove the A/C pressure cut-off switch.
5. Remove the A/C compressor to condenser discharge line nut.
6. Disconnect the A/C compressor to condenser discharge line from the A/C manifold and tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C
Discharge Hose/Line > Page 1275
7. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core and
remove the A/C compressor to condenser discharge
line.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C
Discharge Hose/Line > Page 1276
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line
Condenser To Evaporator Line
REMOVAL
1. Recover the refrigerant.
2. Disconnect the condenser to evaporator tube from the A/C evaporator core.
3. Disconnect the condenser to evaporator tube from the A/C condenser core and remove the
condenser to evaporator tube.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Evaporator to Compressor Suction Line
REMOVAL
1. Disconnect the battery ground cable. 2. Recover the refrigerant.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C
Discharge Hose/Line > Page 1277
3. Disconnect the A/C cycling switch wire harness connector.
4. Remove the A/C cycling switch.
5. Disconnect the evaporator to compressor suction line from the suction accumulator/drier.
6. Disconnect and remove the evaporator to compressor suction line from the A/C manifold and
tube assembly.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Page 1278
Spring Lock Coupling Disconnect Tool Set
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure Hose
To Pump ..............................................................................................................................................
................................................. 40 Nm (30 ft. lbs.) To Gear ................................................................
................................................................................................................................. 20 Nm (15 ft.
lbs.)
Return Hose
To Gear ...............................................................................................................................................
.................................................. 20 Nm (15 ft. lbs.)
Routing Clip .........................................................................................................................................
................................................... 8 Nm (71 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications >
Page 1282
Power Steering Line/Hose: Service and Repair
Removal
1. Refer to the illustration provided for the hose routing and retention points.
Installation
1. When connecting a fitting with a seal ring, a new seal ring must be installed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications >
Page 1283
^ The special tool is used to install the return line connector seal and the pressure line connector
seal.
2. Fill and leak check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications >
Page 1284
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair
Radiator Hose: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Raise the vehicle. 2. Drain the coolant.
3. Remove the lower radiator hose from the radiator.
4. Remove the lower radiator hoses from the oil cooler; (with engine oil cooler). 5. Lower the
vehicle.
6. Remove the lower radiator hose from the degas bottle.
7. Remove the lower radiator hose from the oil filter adapter assembly and remove the lower
radiator hoses from the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Page
1288
Installation
1. NOTE: Position clamps properly.
Follow the removal procedure in reverse order.
2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety
Standard 116. Under this standard, brake fluids are visually different from other automotive fluids
such as transmission, power steering and engine oil.
High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions >
Technician Safety Information
Brake Fluid: Technician Safety Information
SAFETY PRECAUTIONS
WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following
actions:
^ Eye Contact - rinse eyes thoroughly with water.
^ Skin Contact - wash skin with soap and water.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions >
Technician Safety Information > Page 1295
Brake Fluid: Vehicle Damage Warnings
Use clean, fresh Ford High Performance DOT3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3
fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid
meeting Ford specification SAE-J-1704-DOT 4. These types are the only brake fluids that should
be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system.
- Do not use brake fluid that has been stored in an open container.
- Do not mix different types of brake fluid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations
Article No. 01-23-6
11/26/01
^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON
ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION
ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR
2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO
1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002
EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F
SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER
SPORT 2000-2002 F-650, F-750
LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD
MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE
1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002
VILLAGER 1997-2002 MOUNTAINEER
MERKUR: 1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUE This TSB article describes Ford Motor Company's position on the use of propylene
glycol-based engine coolants.
ACTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Recommendations > Page 1300
Ford Motor Company does not recommend nor endorse the use of engine coolants made with
propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene
glycol-based engine coolants.
Published information suggests that engine coolants made with propylene glycol may provide
engine cooling performance equivalent to engine coolants made with ethylene glycol. However,
different brands of engine coolant provide varying corrosion protection for the cooling system. Ford
does not have performance data for the multitude of engine coolants available in the aftermarket
and therefore cannot recommend the use of any coolant except those sold by Ford Customer
Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer
Service Division coolant for the vehicle.
Furthermore, claims of toxicological and environmental advantages of propylene glycol over
ethylene glycol may be misleading. When significant new information is developed, Ford will review
this policy.
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene
glycol-based engine coolants. Those specifications do not refer to engine coolants made with
propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon
the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its
components, the cost of repairing the damage would not be covered by the Ford New Vehicle
Limited Warranty.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Engine Cooling System 15 L
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1303
Coolant: Fluid Type Specifications
Coolant Type .......................................................................................................................................
................................ Ford Premium Engine Coolant
Ford Specification.................................................................................................................................
.........................................................ESE-M97B44-A
Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe
Engine Coolant (orange in color).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1304
Coolant: Service Precautions
DO NOT mix green colored coolant with orange colored coolant.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
A/T Fluid ..............................................................................................................................................
........................................................ 13.1L (13.8 Qt)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1309
Fluid - A/T: Fluid Type Specifications
Item ......................................................................................................................................................
............................................................. Specification
Motorcraft MERCON V Automatic Transmission Fluid
................................................................................................................................... MERCON V
Note: MERCON V is not interchangeable at this time with the current MERCON service fluids.
Check the transmission dipstick to determine the correct fluid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1310
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1311
Fluid - A/T: Service and Repair
1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service,
such as a clutch, band, bearing, etc., is required,
the automatic transmission fluid will also have to be removed for service. At this time, the torque
converter, transmission cooler tubes must be thoroughly flushed to remove any dirt and the
oil-to-air cooler must be replaced.
The oil-to-air cooler must be replaced under the following conditions:
1. Evidence of transmission assembly or fluid contamination is found due to the following
transmission or converter failure modes:
^ major metallic failure
^ multiple clutches or clutch plate failures
2. When used under continuous or severe conditions, the transmission and torque converter should
be drained and refilled with fluid.
^ Normal Maintenance Change fluid at 48,279 km (30,000 miles).
^ Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles).
CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or
failure.
2. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for
the transmission code. 3. When filling a dry transmission and torque converter, refer to
Specifications for capacity. Check the fluid level.
Removal
1. If equipped deactivate the air suspension. 2. Disconnect the battery ground cable 3. Raise the
vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan.
5. Drain transmission fluid.
^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the
bolts.
6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket.
^ Replace transmission fluid pan gasket as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1312
7. Remove torque converter housing plug.
8. Remove the torque converter drain plug and drain the torque converter.
^ Rotate the crankshaft to access the drain plug.
9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C)
magnet.
10. Flush the fluid cooler tubes. 11. Flush the torque converter.
Installation
NOTE: A new torque converter drain plug must be used.
1. Install the torque converter drain plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1313
2. Install the torque converter housing plug.
CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a
small screwdriver to remove the seal. Use care not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
3. Replace fluid filter and seal as required.
4. Position the (B) pan magnet into the (A) transmission fluid pan.
NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not
damaged, the gasket should be reused.
5. Install the transmission fluid pan and gasket.
1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1314
6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped reactivate
the air suspension..
NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts).
10. Fill transmission to proper fluid level.
^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent fluid
meeting Ford specification MERCON V(R).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Capacity
Standard Axle ......................................................................................................................................
.................................................................... 1.8 - 1.9L
Traction-Lok Axle .................................................................................................................................
................................................................. 2.2 - 2.4L
Traction-Lok differentials add 4 oz of friction modifier C8AZ-19B956-A on refill.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 1319
Fluid - Differential: Fluid Type Specifications
Standard Applications
Premium Rear Axle Lubricant SAE 80W90 Specification ....................................................................
........................................................................................................................... WSP-M2C197-A
Police, Taxi, Limo Applications
High Performance Rear Axle Lubricant SAE 75W140 Specification ...................................................
............................................................................................................................................
WSL-M2C192-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1320
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications
Technical Service Bulletin # 02-1-9 Date: 020121
Engine Oil - Oil Recommendations/Applications
Article No. 02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30
MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002
ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002
FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER
1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002
LS 1998-2002 NAVIGATOR
MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999
TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001
MOUNTAINEER
This article is being republished in its entirety to update the vehicle models, engines and years
affected.
NOTE
PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A
COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB.
ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most
gasoline and flexible fueled vehicles.
ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the
recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to
improve fuel economy.
Testing has validated this viscosity grade can be used in many previous model year vehicles. It is
recommended ALL vehicles on the following Vehicle Application Listing be service with SAE
5W-20.
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002
Vehicles" chart are being filled with SAE 5W-20
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 1325
motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
Exception 2002 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED.
REFER TO TSB 99-8-16.
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000
Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 1326
^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 1997-2002 2.0L Escort/Tracer
^ 1998-2002 2.0L Escort ZX2
^ 2000-2002 2.0L Focus
^ 2001-2002 2.0L Escape
^ 1993-1997 2.3L Ranger
^ 1993-1994 2.3L Mustang
^ 1993-1994 2.3L Tempo/Topaz
^ 1998-2001 2.5L Ranger
^ 1995-2000 2.5L Contour/Mystique
^ 1999-2002 2.5L Cougar
^ 2001-2002 3.0L 4V Escape
^ 1996-2001 3.0L 4V Taurus/Sable
^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger,
^ Taurus/Sable (Flexible Fuel and Gas)
^ 1995-2000 3.0L (Vulcan) Windstar
^ 1993-1994 3.0L (Vulcan) Tempo/Topaz
^ 2000-2002 3.0L 4V Lincoln LS
^ 1995-2002 3.8L Windstar
^ 1993-1997 3.8L Taurus/Sable,
^ Thunderbird/Cougar, Continental
^ 1994-2002 3.8L Mustang
^ 2002-2002 3.9L 4V Lincoln LS
^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series
^ 1996-2002 4.6L 2V Mustang
^ 1992-2002 4.6L Crown Victoria/Grand Marquis
^ 1991-2002 4.6L Town Car
^ 1994-1997 4.6L 2V Thunderbird/Cougar
^ 1996-2002 4.6L 4V Mustang Cobra
^ 1995-2002 4.6L 4V Continental
^ 1993-1998 4.6L 4V Mark VIII
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 1327
^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition
^ 1993-1999 4.9L E-Series, F-Series
^ 1993-1995 5.0L Mustang/Mustang Cobra
^ 1993-1993 5.0L Thunderbird/Cougar
^ 1997-2001 5.0L Explorer/Mountaineer
^ 1993-1996 5.0L E-Series, F-Series, Bronco
^ 2000-2002 5.4L Excursion
^ 1998-2002 5.4L 2V/4V Navigator
^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350
Chassis/RV/Cutaway
^ 1993-1997 5.8L F-Series, Bronco
^ 1993-1996 5.8L E-Series
^ 2000-2002 6.8L Excursion
^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway
^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome
^ 1993-1998 7.5L All Vehicles
NOTE
FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV.
NOTE
THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR
OIL
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 1328
Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation
Article No. 99-8-16
05/03/99
MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR
LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999
CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI
1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER
DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999
VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999
NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford
gasoline-powered vehicle regardless of model year.
ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade
motor oil. Refer to the following text for further details.
Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past
depending on vehicle model and model year.
Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and
benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE
5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures.
SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30.
SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum
Institute (API) should be used for all service procedures requiring replacement of the motor oil.
PART NUMBER PART NAME
XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 401000, 490000, 499000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
Capacity ...............................................................................................................................................
................................................ 6.24L (6.6 Qt +/- 0.1)
NOTE: Listed capacities are approximate. Check fluid level after filling.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1331
Engine Oil: Fluid Type Specifications
Engine Oil Type ...................................................................................................................................
............................................................... SAE 5W-20
NOTE: Refer to TSB# 02-1-9
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1332
Engine Oil: Service Precautions
SAFETY PRECAUTIONS
WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer.
Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Do not put oily rags in pockets.
- Avoid contaminating clothes, particularly underpants, with oil.
- Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be
cleaned regularly.
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to help the removal of oil from the
skin.
- Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanolin replace the natural skin oils which have been removed.
- Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay.
- Where practicable, degrease components prior to handling.
- Where there is a risk of eye contact, eye protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash facility should be provided.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER
STEERING SYSTEMS
FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort
2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle
2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53
Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005
Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007
Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series
2000-2007 F-650, F-750 2006-2007 Low Cab Forward
LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln
LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator
2006-2007 Mark LT 2007 MKX
MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar
2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002
Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid for power steering systems originally requiring MERCON(R).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1337
ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be
serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids
labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission
Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining
inventory has been depleted.
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V.
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER
STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY
OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Page 1338
Power Steering Fluid: Specifications
Use Motorcraft MERCON(r) Multi-Purpose ATF, XT-2-QDX or equivalent MERCON(r) approved
fluid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Page 1339
Power Steering Fluid: Service Precautions
CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may
result.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants
Technical Service Bulletin # 99-19-6 Date: 990920
A/C - Identification of Non Approved Refrigerants
Article No. 99-19-6
09/20/99
^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS
^ AIR CONDITIONING - PURGING AIR FROM SYSTEM
FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD
1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA
1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO
II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD,
RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000
WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991
CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO
SERIES 1997-1998 AEROMAX, LOUISVILLE
LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000 LS 1998-2000 NAVIGATOR
MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR
1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI
1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER
1997-2000 MOUNTAINEER
MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1344
This TSB article is being republished in its entirety to add model year vehicles
ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are
being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved
refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety,
durability, and performance concerns if they are installed in Ford A/C systems. Identification of the
type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent
dealer service equipment and refrigerant supplies from being contaminated with non-approved
refrigerants.
ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a
recovery machine to prevent cross-contamination of the recovery machine and other A/C systems
being serviced with that recovery machine. Refer to the following text.
OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4
SUPERSEDES: 98-12-8
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
991906A Test A/C System For 0.3 Hr.
Contaminated Refrigerant
DEALER CODING
CONDITION
BASIC PART NO. CODE
R-12 49
OASIS CODES: 208000, 208999
A/C Refrigerant Analyzer Function
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1345
Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for
use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a
quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or
flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system
and automatically purge air from the system.
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from
automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes
through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor
calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid
Crystal Display (LCD).
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the
sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green
"PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity
levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will
light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and
"HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards.
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or
above. The analyzer eliminates the effect of air
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1346
when determining the refrigerant sample content because air is not considered a contaminant
although air can affect A/C system performance. Air will automatically be purged until a pure
refrigerant with a less than 2% by weight air measurement is reached.
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12
recovery/recycling equipment. Take the following actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any additional cost to repair the
system. The customer may wish to return to the service facility which performed the last A/C
service.
3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover
contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C
service facility in your area which has the proper equipment for refrigerant recovery.
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the
system. Ford recommends that you do the following to be sure a quality repair is made:
1. Determine the cause of the failure.
2. Determine which parts will need to be replaced.
3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated
refrigerant.
4. Install a new suction/accumulator.
5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present
in the system.
6. Evacuate the system for 45 minutes.
7. Recharge the system, verify proper operation, and leak test.
Disposal of Contaminated Refrigerant
Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are
companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not
evaluated the processes of the listed refrigerant disposal companies and is not endorsing or
promoting their companies Business transactions are between the dealership and disposal
companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip
cylinder shipping.
^ Omega Refrigerant Reclamation
^ 5263 North Fourth St.
^ Irwindale, CA 91706
^ (310) 698-0991 FAX: (310) 696-7908
^ Full Cycle Global
^ 2966 Wireton
^ Blue Island, IL 60406
^ (708) 388-8551 FAX: (708) 399-6550
^ U.S. Refrigerant Reclaim, Inc.
^ 12420 North Green River Road
^ Evansville, IN 47711
^ (800) 207-5931 FAX: (812) 867-1463
^ Full Cycle Global
^ 343 South Airline Highway
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1347
^ Gonzales, LA 70737
^ (504) 644-5333 FAX: (504) 644-1609
^ CFC Reclamation
^ 1321 Swift North
^ Kansas City, MO 64116
^ (816) 471-2511
^ Full Cycle Global
^ 550 James St.
^ Lakewood, NJ 08701
^ (908) 370-3400 FAX: (908) 370-3088
^ National Refrigerants, Inc.
^ 11401 Roosevelt Blvd.
^ Philadelphia, PA 19154
^ (215) 698-6620 FAX: (215) 602-8205
^ Gartech Refrigerant Reclamation
^ 2002 Platinum
^ Garland, TX 75042
^ (214) 272-4070 FAX: (214) 272-6548
^ Refrigerant Reclaim Services
^ 121 S. Norwood Dr.
^ Hurst, TX 76053-7807
^ (817) 282-0022 FAX: (800) 831-6182
^ Full Cycle Global
^ 2055 Silber, Suite 109
^ Houston, TX 77055
^ (713) 681-7370 FAX: (713) 681-9947
^ Refrigerant Reclaim, Inc.
^ 122 Old Stage Coach Road
^ Dumfries, VA 22026
^ (800) 238-5902 FAX: (703) 441-0393
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant Capacity ............................................................................................................................
........................................................... 1.08 kg (38 oz)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1350
Refrigerant: Fluid Type Specifications
Refrigerant............................................................................................................................................
........................................................................R134a
Ford Part Number ................................................................................................................................
..................................................................... YN-19
Ford Specification ................................................................................................................................
................................................... WSH-M17B19-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Oil Capacity .........................................................................................................................................
........................................................... 222 ml (7.5 oz)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1355
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil......................................................................................................................................
...Polyalkylene Glycol (PAG) Oil (R-134a Systems)
Ford Part Number
...........................................................................................................................................................
F7AZ-19589-AD (MC-YN-12C)
Ford Specification ................................................................................................................................
.................................................. WSH-M1C231-B
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure
Brake Bleeding: Service and Repair Caliper Bleeding Procedure
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the Brake Pedal (BP) and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1360
Brake Bleeding: Service and Repair Manual Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of a
new part, 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. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash
and follow the NGS instructions.
2. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the
tube in a container partially filled with clean brake fluid.
4. Have an assistant hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw
until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal,
tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1361
6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw.
8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder
screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
9. Have an assistant hold firm pressure on the brake pedal.
10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out.
While the assistant maintains pressure on the brake
pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
11. Tighten the RH front disc brake caliper bleeder screw. 12. Repeat Steps 8, 9, 10 and 11 for the
LH front disc brake caliper bleeder screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1362
Brake Bleeding: Service and Repair Master Cylinder Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can enter the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be
bled manually or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been replaced or the system has been emptied, or
partially emptied, it should be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines.
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill
the brake master cylinder reservoir with High
Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A.
4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid
flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at
the bench, install it in the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1363
6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the
brake master cylinder as follows:
1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
2 Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
3 Repeat this operation until clear, bubble-free fluid comes out.
4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1364
Brake Bleeding: Service and Repair Pressure Bleeding
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending
with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1365
Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS)
NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS)
Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened.
NOTE: Ford provides no information or procedures to bleed the brake system without the Rotunda
New Generation Star (NGS) tester/scan tool.
1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of
brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding
Procedure > Page 1366
4. Tighten the RH rear bleeder screw, and disconnect the waste line.
5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder
screw, and the LH front disc brake caliper bleeder
screw, in that order.
6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the
dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps
1 through 5.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Arming and Disarming > Page 1372
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1378
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1379
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1380
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1381
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1382
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1383
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1384
Circuit Breaker: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1385
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1386
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1387
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1388
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1389
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Diagram Information and Instructions > Page 1390
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Battery Junction Box
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Battery Junction Box > Page 1395
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1398
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1399
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1400
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1401
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1402
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1403
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1404
Fuse: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1405
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1406
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1407
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1408
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1409
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1410
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Battery Junction Box
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Battery Junction Box > Page 1413
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1418
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1419
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1420
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1421
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1422
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1423
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1424
Fuse Block: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1425
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1426
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1427
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1428
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1429
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1430
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
High Current Relay Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
High Current Relay Center > Page 1435
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
High Current Relay Center > Page 1436
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
SERVICE ENGINE SOON
Your vehicle is equipped with a computer that monitors the engine's emission control system. This
is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the
environment by ensuring that your vehicle continues to meet government emission standards. The
OBD II system also assists the service technician in properly servicing your vehicle.
The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON
position to check the bulb. If it comes on after the engine is started, on of the engine's emission
control systems may be malfunctioning. The light may illuminate without a driveability concern
being noted. The vehicle will ususally be drivable and will not require towing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation > Page 1441
Maintenance Required Lamp/Indicator: Service and Repair
Solid SERVICE ENGINE SOON light
This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary
malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or
water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened.
The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or
properly installing and securely tightening the gas cap. After three driving cycles with out these or
any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A
driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No
additional vehicle service is required.
Blinking SERVICE ENGINE SOON light
Engine misfire is occurring which could cause damage to your catalytic converter. You should drive
in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced
at the first available opportunity.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED
indicator.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Suspension Warning Indicator > Component
Information > Description and Operation
Suspension Warning Indicator: Description and Operation
The CHECK AIR SUSPENSION warning indicator illuminates when a concern in the air suspension
system is detected or when the air suspension switch is in the OFF position. During prove-out,
when a concern is detected or the air suspension switch is OFF, an audible tone will sound and the
CHECK AIR SUSPENSION warning indicator will flash on and off for five seconds. The CHECK
AIR SUSPENSION warning indicator will then remain illuminated until the concern is corrected or
the air suspension switch is switched ON.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
Technical Service Bulletin # 00S13 Date: 000701
Recall - Vehicle Jacking Procedure
SAFETY RECALL 00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment II ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1457
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought
to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1458
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of
the Owner Letter and schedule a service date.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARS Rental vehicles are not approved for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage
label, and a jack usage and stowage placard will be sent directly to owners, along with instructions
on placement of the various pieces. This will be a "no charge" service and customers will be
directed to follow the attached instructions for proper placement of the labels and owner guide
supplement.
Additional owner packages containing the above mentioned items can be ordered by calling the
Recall Hotline at 1-800-325-5621.
Attachment III - Technical Information
OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the
vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.
^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1459
1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located
in the glove compartment. See Figure 1.
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by
removing the right quarter trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1460
2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the
underside of the spare tire cover.
1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and
Stowage label directly over the original label as illustrated. See Figure 3.
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1461
1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing
Instruction placard on top of the spare tire as illustrated. See Figure 4.
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1462
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1463
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
Technical Service Bulletin # 00S13 Date: 000701
Recall - Vehicle Jacking Procedure
SAFETY RECALL 00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment II ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1469
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought
to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1470
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of
the Owner Letter and schedule a service date.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARS Rental vehicles are not approved for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage
label, and a jack usage and stowage placard will be sent directly to owners, along with instructions
on placement of the various pieces. This will be a "no charge" service and customers will be
directed to follow the attached instructions for proper placement of the labels and owner guide
supplement.
Additional owner packages containing the above mentioned items can be ordered by calling the
Recall Hotline at 1-800-325-5621.
Attachment III - Technical Information
OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the
vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.
^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1471
1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located
in the glove compartment. See Figure 1.
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by
removing the right quarter trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1472
2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the
underside of the spare tire cover.
1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and
Stowage label directly over the original label as illustrated. See Figure 3.
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1473
1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing
Instruction placard on top of the spare tire as illustrated. See Figure 4.
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1474
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure >
Page 1475
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Page 1476
Vehicle Lifting: Description and Operation
JACKING
WARNING
^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO
THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE.
THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE
AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE
LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF
THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE
OPERATIONS.
^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO
MOVE.
CAUTION
^ The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose. Refer to the Owner Guide when using the jack supplied with the vehicle.
^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer
or differential housing. Severe damage to the vehicle could result.
^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure.
Jacking Points
Push the air suspension service switch to the OFF position.
To lift the front or either side of the front end, position the floor jack or the hoist under the front
frame lift points.
To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift
points.
LIFTING
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER
SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE
VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING
OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT
ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
CAUTION
^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Page 1477
^ Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.
Lift the vehicle using the Lifting Points procedure.
Lifting Points-Drive-On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the
drive-on hoist without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance.
Lifting Points-Two Post Lift
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Page 1478
Lifting Points-Single-Post Hoist
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Page 1479
Vehicle Lifting: Service and Repair
JACKING
WARNING
^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO
THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE.
THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE
AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE
LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF
THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE
OPERATIONS.
^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO
MOVE.
CAUTION
^ The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose. Refer to the Owner Guide when using the jack supplied with the vehicle.
^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer
or differential housing. Severe damage to the vehicle could result.
^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure.
Jacking Points
Push the air suspension service switch to the OFF position.
To lift the front or either side of the front end, position the floor jack or the hoist under the front
frame lift points.
To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift
points.
LIFTING
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER
SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE
VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING
OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT
ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
CAUTION
^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Page 1480
^ Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.
Lift the vehicle using the Lifting Points procedure.
Lifting Points-Drive-On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the
drive-on hoist without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance.
Lifting Points-Two Post Lift
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service
Bulletins > Page 1481
Lifting Points-Single-Post Hoist
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications
Spare Tire: Specifications
Wheel Size ..........................................................................................................................................
...................................................................... 16 x 4.5 Bolt Circle .......................................................
...................................................................................................................................... 114.3 mm
(4.5 inch) Lugs .....................................................................................................................................
................................................................................................. 5 Offset ..............................................
..............................................................................................................................................................
............ 9 (inset) Tire Usage ................................................................................................................
............................................................................... T145/80D16 105M
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels
Wheels: Customer Interest Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels
Wheels: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 1503
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis
Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1508
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1509
For Dealerships without An Electronic Vibration Analyzer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1510
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1511
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1512
Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1517
Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1518
^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1519
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1520
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1521
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Procedure > Page 1524
The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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Procedure > Page 1525
g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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Procedure > Page 1526
engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Procedure > Page 1527
^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Procedure > Page 1528
Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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Procedure > Page 1529
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1530
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1531
To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
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Procedure > Page 1532
^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Procedure > Page 1534
Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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Procedure > Page 1535
^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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Procedure > Page 1536
^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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Procedure > Page 1537
- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1538
Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1539
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1540
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1541
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1542
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1543
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1544
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1545
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1546
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1547
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1548
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1549
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1550
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1551
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1552
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1553
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1554
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1555
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1556
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1557
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1558
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1559
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1560
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1561
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1562
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1563
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1564
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1565
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1566
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1567
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1568
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1569
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1570
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1571
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1572
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1573
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1574
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1575
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1576
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1577
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1578
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1579
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1580
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1581
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1582
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1583
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1584
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1585
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1586
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1587
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1588
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1589
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1590
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1591
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1592
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1593
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1594
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1595
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1596
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1597
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1598
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1599
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1600
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1601
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1602
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1603
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1604
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1605
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1606
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1607
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
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Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
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Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1609
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
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Procedure > Page 1610
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
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Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1611
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
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Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 1617
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis
Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
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Page 1622
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Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1623
For Dealerships without An Electronic Vibration Analyzer
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Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1624
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Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis >
Page 1625
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
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Page 1626
Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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Procedure > Page 1632
^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Procedure > Page 1634
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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Procedure > Page 1635
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Procedure > Page 1636
Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Procedure > Page 1637
Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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Procedure > Page 1638
The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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Procedure > Page 1639
g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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Procedure > Page 1641
^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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Procedure > Page 1643
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1644
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1645
To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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Procedure > Page 1646
^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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Procedure > Page 1647
speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Procedure > Page 1648
Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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Procedure > Page 1649
^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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Procedure > Page 1650
^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1651
- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1652
Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1653
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1654
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1655
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1656
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1657
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1658
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1659
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1660
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1661
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1662
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1663
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1664
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1665
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1666
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1667
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1668
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1669
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1670
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1671
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1672
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1673
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1674
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1675
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1676
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1677
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1678
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1679
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1680
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1681
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1682
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1683
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1684
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1685
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1686
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1687
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1688
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1689
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1690
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1691
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1692
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1693
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1694
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1695
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1696
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1697
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1698
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1699
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1700
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1701
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1702
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1703
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1704
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1705
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1706
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1707
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1708
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1709
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1710
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1711
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1712
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1713
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1714
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1715
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1716
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1717
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1718
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1719
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1720
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1721
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1722
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1723
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness
Procedure > Page 1724
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Procedure > Page 1725
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1726
Wheels: Specifications
Bolt Circle ............................................................................................................................................
................................................. 114.3 mm (4.5 inch) Balance Weights, Max.
Per Wheel ............................................................................................................................................
...................................................... 140 g (5.0 oz.) Per Side ................................................................
......................................................................................................................................... 70 g (2.5
oz.)
Lugs .....................................................................................................................................................
................................................................................. 5 Offset
Steel ....................................................................................................................................................
.......................................................................... 11 Aluminum .............................................................
.........................................................................................................................................................
4.5
Runout, Max
Radial ..................................................................................................................................................
............................................. 0.64 mm (0.025 inch) Lateral .................................................................
............................................................................................................................. 0.89 mm (0.035
inch)
Size ......................................................................................................................................................
......................................................................... 16 x 7
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1727
Wheels: Testing and Inspection
TIRE AND WHEEL RUNOUT
Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration,
wheel tramp, tire wear, and steering wheel tremor.
Before checking runout, and to avoid false readings caused by temporary flat spots in the tires,
check runout only after the vehicle has been driven far enough to warm the tires.
The extent of the runout is measured with the radial runout gauge. All measurements are made on
the vehicle with the tires inflated to recommended inflation pressures.
TIRE RUNOUT
Measure radial and lateral tire runout at the positions shown in the illustration. Runout should not
exceed specifications.
WHEEL RUNOUT
Measure radial and lateral wheel runout at the positions shown in the illustration. Runout should not
exceed specifications. Note that the tire has been removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Leaks
Wheels: Service and Repair Leaks
NOTE: Wheel repairs that use welding or peening are not approved. An inner tube is not an
acceptable repair for leaking wheels or tires.
If the air pressure in a tire mounted on an aluminum wheel is found to be low, perform the following
procedure before considering wheel replacement.
1. Remove the tire and wheel assembly, and inspect the wheel for structural damage. If none
exists, go to Step 2. If the wheel is damaged, install new. 2. With the tire mounted on the wheel,
locate the air leak using a water bath or equivalent method, and mark the location. Check the
complete wheel
for possible additional leaks. When leaks are marked, dismount the tire marking valve location on
the tire for correct indexing.
3. On the tire side of the wheel, thoroughly clean the leaking area with an appropriate cleaner
(Professional Choke and Linkage Cleaner
E8AZ-19A501-AA or equivalent meeting Ford specification ESR-M14P10-A) or use sandpaper of
approximately 80-grit to remove all contamination. Using the sandpaper, score the surface of the
leaking area to improve adhesion of the sealer. If the valve stem is close to the area, remove it.
4. Use a clean cloth to remove all cleaner or sanding dust.
5. NOTE: Do not use a torch containing oxyacetylene.
Heat the prepared area with a Heat Gun or a propane torch until Aluminum Wheel Repair
Compound E7AZ-19554-A or equivalent meeting Ford specification ESA-M4G280-A flows. Apply
the hot melt material over the prepared area using a liberal flow and wiping action. Repair is most
effective when heat is applied to the brake side of the rim, and the sealer is melted by heat in the
metal.
6. Apply only enough heat to melt the sealer, then remove the heat source. After repairing the leak,
allow the wheel to cool until it can be handled
safety.
7. CAUTION: Use caution when mounting the tire so as not to damage the sealer.
Index and assemble the tire and wheel. Inflate the tire to the recommended pressure as indicated
on the tire pressure decal.
8. Repeat Step 2 to verify repair. 9. When the repair is completed, balance the assembly and install
it on the vehicle.
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Leaks > Page 1730
Wheels: Service and Repair Replacement
Removal
1. Loosen the lug nuts.
1 Remove the wheel cover or ornament.
2 CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel
bearings.
Loosen, but do not remove the lug nuts.
2. CAUTION: Never use the differential housing as a lift point.
Raise the vehicle until the tire clears the floor.
3. CAUTION: Do not use heat to loosen a frozen wheel because heat can shorten the life of the
wheel and damage the wheel bearings. If the
wheel cannot be removed by hand, use a wheel puller to remove the frozen wheel.
Remove the wheel and tire from the vehicle. ^
Remove the lug nuts.
^ Remove the wheel and tire.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug
nuts to loosen and the wheel to come off while the vehicle is in motion, resulting in loss of control.
Position the wheel and tire on the vehicle.
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2. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of
brake roughness, shudder and vibration.
Tighten the lug nuts to specification in a star-pattern sequence.
3. Install the wheel cover or ornament.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1736
Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1738
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1739
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1740
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
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Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
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Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
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^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
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^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
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Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
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CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
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3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
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Wheel Bearing: Service Precautions
CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the
improper grease can cause bearing damage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1832
Wheel Bearing: Testing and Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new
wheel hub.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1833
Wheel Bearing: Service and Repair
FRONT WHEEL HUB
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. Remove and discard the front hub cap grease seal.
5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it
can back off resulting in loss of the front
wheel and or damage to the wheel hub and bearing assembly.
Remove the front axle wheel hub retainer. Discard the retainer.
6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS
sensor lead or the ABS sensor ring.
NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to
remove.
Remove the wheel hub and bearing assembly.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1834
1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the
ABS sensor lead or the ABS sensor ring.
Install the wheel hub and bearing assembly.
2. Install a new front axle wheel hub retainer.
3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire
assembly. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Axle Wheel Hub Retainer
...........................................................................................................................................................
300 Nm (221 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake roughness, shudder and vibration.
Tighten the lug nuts to 115-142 Nm (85-105 ft. lbs.) in a star-pattern sequence.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
Special Tools
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage
the ABS sensor lead or the ABS sensor
ring.
Using the special tool, press the wheel stud out of the wheel hub and bearing flange.
Installation
1. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage
the ABS sensor lead or the ABS sensor
ring.
Position the wheel stud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1844
2. Install the wheel stud.
1 Install four washers onto the wheel stud.
2 Install reversed wheel nut. Tighten the wheel nut until the wheel stud seats fully onto the wheel
hub and bearing flange.
3. Remove the wheel nut and washers. 4. Install the brake disc. 5. Install the wheel and tire
assembly. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1845
Wheel Fastener: Service and Repair Rear
Special Tools
Removal
Special Tools
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off (If equipped).
2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove rear brake
disc.
5. Using the special tool, press the lug bolt from its seat and discard.
Installation
CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1846
1. Insert a new lug bolt in the hole in the axle flange, making sure serrations are aligned with those
in the flange.
2. Place four flat washers over the outside end of the lug bolt, and thread a standard lug nut with
the flat side against the washers. 3. Tighten the lug nut until the lug bolt head seats against the
back side of the axle flange. 4. Remove the lug nut and washers. 5. Install the rear brake disc. 6.
Install the wheel and tire assembly. 7. Lower the vehicle.
8. Turn the air suspension service switch on (If equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Page 1847
Wheel Fastener: Tools and Equipment
Special Tool
Special Tool
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
Technical Service Bulletin # 00S13 Date: 000701
Recall - Vehicle Jacking Procedure
SAFETY RECALL 00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment II ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1856
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought
to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1857
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of
the Owner Letter and schedule a service date.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARS Rental vehicles are not approved for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage
label, and a jack usage and stowage placard will be sent directly to owners, along with instructions
on placement of the various pieces. This will be a "no charge" service and customers will be
directed to follow the attached instructions for proper placement of the labels and owner guide
supplement.
Additional owner packages containing the above mentioned items can be ordered by calling the
Recall Hotline at 1-800-325-5621.
Attachment III - Technical Information
OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the
vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.
^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1858
1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located
in the glove compartment. See Figure 1.
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by
removing the right quarter trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1859
2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the
underside of the spare tire cover.
1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and
Stowage label directly over the original label as illustrated. See Figure 3.
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1860
1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing
Instruction placard on top of the spare tire as illustrated. See Figure 4.
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1861
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls
for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1862
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
Technical Service Bulletin # 00S13 Date: 000701
Recall - Vehicle Jacking Procedure
SAFETY RECALL 00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment II ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1868
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought
to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1869
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of
the Owner Letter and schedule a service date.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARS Rental vehicles are not approved for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage
label, and a jack usage and stowage placard will be sent directly to owners, along with instructions
on placement of the various pieces. This will be a "no charge" service and customers will be
directed to follow the attached instructions for proper placement of the labels and owner guide
supplement.
Additional owner packages containing the above mentioned items can be ordered by calling the
Recall Hotline at 1-800-325-5621.
Attachment III - Technical Information
OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the
vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.
^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1870
1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located
in the glove compartment. See Figure 1.
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by
removing the right quarter trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1871
2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the
underside of the spare tire cover.
1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and
Stowage label directly over the original label as illustrated. See Figure 3.
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1872
1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing
Instruction placard on top of the spare tire as illustrated. See Figure 4.
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1873
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1874
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page
1875
Vehicle Lifting: Description and Operation
JACKING
WARNING
^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO
THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE.
THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE
AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE
LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF
THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE
OPERATIONS.
^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO
MOVE.
CAUTION
^ The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose. Refer to the Owner Guide when using the jack supplied with the vehicle.
^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer
or differential housing. Severe damage to the vehicle could result.
^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure.
Jacking Points
Push the air suspension service switch to the OFF position.
To lift the front or either side of the front end, position the floor jack or the hoist under the front
frame lift points.
To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift
points.
LIFTING
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER
SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE
VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING
OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT
ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
CAUTION
^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page
1876
^ Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.
Lift the vehicle using the Lifting Points procedure.
Lifting Points-Drive-On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the
drive-on hoist without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance.
Lifting Points-Two Post Lift
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page
1877
Lifting Points-Single-Post Hoist
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page
1878
Vehicle Lifting: Service and Repair
JACKING
WARNING
^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO
THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE.
THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE
AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE
LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF
THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE
OPERATIONS.
^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO
MOVE.
CAUTION
^ The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose. Refer to the Owner Guide when using the jack supplied with the vehicle.
^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer
or differential housing. Severe damage to the vehicle could result.
^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure.
Jacking Points
Push the air suspension service switch to the OFF position.
To lift the front or either side of the front end, position the floor jack or the hoist under the front
frame lift points.
To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift
points.
LIFTING
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER
SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE
VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING
OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT
ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
CAUTION
^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page
1879
^ Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.
Lift the vehicle using the Lifting Points procedure.
Lifting Points-Drive-On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the
drive-on hoist without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance.
Lifting Points-Two Post Lift
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page
1880
Lifting Points-Single-Post Hoist
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1886
Compression Check: Testing and Inspection
Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the
battery is properly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons
in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating improperly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1887
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications
Camshaft Bearing: Specifications
Camshaft Bearing Cap Bolts 8-12 Nm (71.4-107.1 in.lb)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
TORQUE SPECIFICATIONS
Camshaft Sprocket Bolt
........................................................................................................................................................
110-130 Nm (81-95 Ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications
Camshaft: Specifications
Lobe Lift-Exhaust LH 6.59579 mm
RH 6.58551 mm
Lobe Lift-Intake 6.58077 mm
Lobe Lift-Allowable Lobe Lift Loss 0 mm
Theoretical Valve Lift @ Zero Lash-Intake 0.472 in
Theoretical Valve Lift @ Zero Lash-Exhaust 0.472 in
End Play .027-.190 mm
End Play-Service Limit .0075 in
Journal To Bearing Clearance .00098-.003 in
Tighten Camshaft Bearing Caps Bolts To 8-12Nm
(72-107lb/in) When Measuring Journal Clearance.
Journal To Bearing Clearance(Service Limit) .076 mm
Tighten Camshaft Bearing Caps Bolts To 8-12Nm
(72-107lb/in) When Measuring Journal Clearance.
Journal Diameter(ALL) (1.060-1.061) in
Journal Diameter-Bearing Inside Diameter (1.0625-1.063) in
Camshaft Journal Runout 0.09 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1898
Camshaft: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1899
Camshaft: Service and Repair
Removal
1. Remove the valve cover. 2. Remove the timing chain.
3. CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed
may the crankshaft or camshaft be
rotated. Severe piston and valve damage will occur.
Remove the camshaft roller followers.
4. Remove the camshaft sprocket
1 Remove the bolt.
2 Remove the camshaft sprocket.
5. Remove the thirteen camshaft bearing cap bolts.
6. Remove the camshaft bearing cap ladders.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1900
7. Remove the camshaft from the cylinder head.
Installation
1. Lubricate the camshaft journals.
^ Use Ford Super premium SAE 5W30 Motor oil XO-5W30-QSP or equivalent meeting Ford
specification WSS-M2C153-G.
2. Install the camshaft onto the cylinder head.
3. Lubricate the camshaft bearing cap ladders.
^ Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford
specification WSS-M2053-6.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1901
4. Install the camshaft bearing caps and loosely install the bolts.
5. Tighten the bolts in the sequence shown.
6. Install the camshaft sprocket spacer.
1 Position the camshaft sprocket and sprocket spacer.
2 Install the bolt.
7. Install the roller follower.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1902
8. Install the timing chains. 9. Install the valve cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1903
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications
Lifter / Lash Adjuster: Specifications
Lash Adjuster-Diameter (STD) (0.629-0.63) in
Lash Adjuster-Clearance To Bore (0.00071-0.00272) in
Lash Adjuster-Service Limit (0.00063) in
Lash Adjuster-Hydraulic Leakdown Rate 5-25 sec
Tighten Camshaft Bearing Cap Bolts To 8-12Nm(72-107Lb/in)
When Measuring Journal Clearance
Lash Adjuster-Collapsed Adjuster gap-Desired (0.0177-0.0335) in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications > Page 1907
Lifter / Lash Adjuster: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications > Page 1908
Lifter / Lash Adjuster: Service and Repair
HYDRAULIC LASH ADJUSTERS
Removal
1. Remove the camshaft roller followers.
2. Remove the valve tappets.
Installation
1. Install the valve tappets. 2. Install the camshaft roller followers.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm-Ratio 1.75 : 1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1912
Rocker Arm Assembly: Service and Repair
Special Tools
ROLLER FOLLOWERS
Removal
1. Remove the valve cover.
2. Position the piston of the cylinder being repaired at the bottom of the stroke.
3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal
damage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1913
4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller
followers.
Installation
1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C)
camshaft roller followers.
2. Remove the Valve Spring Spacer. 3. Install the valve cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications Connecting Rod Bearings
Connecting Rod Bearings
Clearance to Crankshaft Desired 0.024-0.066 mm
Allowable 0.026-0.064 mm
Bearing Wall Thickness Std. 1.921-1.927 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt
Connecting Rod: Specifications
Connecting Rod Cap Bolts Stage 1 40-45 Nm (30-33 ft.lb)
Stage 2 Rotate 90°-120°
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt > Page 1922
Connecting Rod: Specifications
Connecting Rod-Piston Pin Bore Dianeter 22.012-22.024 mm
Connecting Rod -To Piston Clearance 3.10-4.00 mm
Connecting Rod-Crankshaft Bearing Bore 56.866-56.886 mm
Connecting Rod(Center To Center)Length 5.93 in
Alignment-Bore to Bore +/-0.05 mm
>Pin Bore And Crank Bearing Bore Must Be Parallel And In Same
Vertical Plane Within The Specified Total Difference When
Measured At The Ends Of A 203mm (8.12in) Bar, 105mm (4.06in) On
Each Side Of Rod Centerline,-Twist mm(inch).
Alignment-Bore To Bore-Max Diff +/-0.038 mm
Side Clearance-Assembled To Crank-Standard 0.0006-0.0117 in
Side Clearance-Assembled To Crank-Service Limit (MAX) 0.02 in
Connecting Rod Bolts Stage 1 30-33 ft.lb
Stage 2 Rotate 90-120 Degrees
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt > Page 1923
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 1924
Connecting Rod: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug,
Cylinder Block > Component Information > Specifications
Coolant Drain Plug: Specifications
Cylinder Block Drain Plug 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket >
Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Stage 1 66 ft.lb
Stage 2 Loosen 360 Degrees
Stage 3 35-39 ft.lb
Stage 4 Rotate 85-90 Degrees
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
Jack Screws Stage 1 5 Nm (44.6 in.lb)
Stage 2 9-11 Nm (80-97 in.lb)
Main Bearing Cap Bolts Stage 1 10 Nm (89.2 in.lb)
Stage 2 19-23 Nm (14-17 ft.lb)
Main Bearing Clearance to Crankshaft - Desired 0.024-0.066 mm
Clearance to Crankshaft - Allowable 0.024-0.066 mm
Bearing Wall Thickness - (Std.) 1.921-1.927 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 1934
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Main Journal Diameter 2.65-2.657 in
Connecting Rod Journal-Diameter 2.087-2.867 in
Crankshaft Main Bearing Journal Taper 0.003 in
Crankshaft Main Bearing Journal Runout 0.002 in
Crankshaft Connecting Rod Journal Taper 0.0005 in
Crankshaft End Play 0.129-0.301 in
Crankshaft Runout To Rear Face Of Block (MAX) 0.002 in
Connecting Rod Clearance To Crankshaft-Desired 0.024-0.066 mm
Connecting Rod Clearance To Crankshaft-Allowable 0.024-0.066 mm
Connecting Rod Bearing Wall Thickness (STD) 1.921-1.927 mm
Main Bearing Journal To Crankshaft-Desired 0.024-0.066 mm
Main Bearing Journal To Crankshaft-Allowable 0.024-0.066 mm
Main Bearing Wall Thickness(STD) 1.921-1.927 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 1938
Crankshaft: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 1939
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications
Engine Block Heater: Specifications
Block Heater Screw 14-16 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications > Page 1943
Engine Block Heater: Service and Repair
Removal
CAUTION: Do not mix Standard (green) Coolant with Extended Life Coolant (orange).
1. Drain the engine cooling system.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which
may result in shifting of the vehicle during these operations.
Raise and support the vehicle.
3. Disconnect the (A) block heater wiring from the (B) block heater.
4. Remove the block heater.
1 CAUTION: Do not loosen the screw more than necessary for removal.
Loosen the screw.
2 Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip.
Installation
1. NOTE: To ease installation, coat the block heater seal and the cylinder block hole with
Motorcraft Premium Long Life Grease XG-1-C or
equivalent meeting Ford specification ESA-M1C75-B.
NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications > Page 1944
Lower the vehicle. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair
Expansion/Freeze Plug: Service and Repair
Special Tools
CORE PLUG REPLACEMENT
1. Use a slide hammer or tools suitable to remove the cylinder block core plug. 2. Inspect the
cylinder block plug bore for any damage that would interfere with the proper sealing of the plug. If
the cylinder block plug bore is
damaged, bore for the next oversize plug.
3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the
plug.
Coat the cylinder block core plug and bore lightly with Threadlock(R) 262 E2FZ-19554-B or
equivalent meeting Ford specification WSK-M2G351-A6 and install the cylinder block core plug.
Cup-Type
1. CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface.
CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to
effectively seal the bore.
Use a tooling suitable to seat the cup type cylinder block core plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair > Page 1948
Expansion-Type
1. CAUTION: Do not contact the crown when installing an expansion type cylinder block core
plug.This could expand the plug before
seating and result in leakage.
Use tooling suitable to seat the expansion type cylinder block core plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair > Page 1949
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley Bolt Stage 1 66 ft.lb
Stage 2 Loosen 360 Degrees
Stage 3 35-39 ft.lb
Stage 4 Rotate 85-90 Degrees
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1953
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Special Tools
Removal
1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt.
3. Remove the crankshaft pulley bolt.
4. Use the Crankshaft Damper Remover to remove the crankshaft pulley.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1954
1. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone.
Apply silicone to the woodruff key slot on the crankshaft pulley. Use Silicone Gasket and Sealant
F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.
2. Use the Crankshaft Damper Replacer to install the crankshaft pulley.
3. Install the bolt and washer. Tighten the bolt in four steps.
^ Step 1: Tighten to 90 Nm (66 ft. lbs.).
^ Step 2: Loosen the bolt.
^ Step 3: Tighten to 47-53 Nm (34-39 ft. lbs.).
^ Step 4: Tighten an additional 85-90 degrees.
4. Install the drive belt. 5. Install the engine cooling fan and the fan shroud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston To Bore Clearance (@ 43mm From Top) With Coating -0.005- +0.025 mm
Pin Bore Diameter 10:1 Engines 21.9985-22.0025 mm
9:1 Engines 22.0065-22.0110 mm
Ring Groove Width-Compression (Top) 10:1 Engines 1.23-1.25 mm
9:1 Engines 1.52-1.54 mm
Ring Groove Width-Compression (Bottom) 10:1 Engines 1.52-1.54 mm
9:1 Engines 1.52-1.54 mm
Ring Groove Width-Oil Ring 10:1 Engines 3.03-3.055 mm
9:1 Engines 3.03-3.055 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 1958
Piston: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 1959
Piston: Service and Repair
For further information regarding this component, please refer to Engine; Service and Repair;
Disassembly and Assembly of Subassemblies.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston Pin-Length 10:1 Engines 61.601-62.030 mm
9:1 Engines 61.870-62.120 mm
Piston Pin-Diameter 10:1 Engines 22.0010-22.0030 mm
9:1 Engines 21.995-21.997 mm
PIn To Piston Clearance 10:1 Engines 0.0045 Interference To 0.0015 Clearance mm
9:1 Engines 0.0095-0.016 mm
Pin To Rod Clearance 10:1 Engines 0.009-0.0023 mm
9:1 Engines Fixed Pin
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Ring To Groove Clearance Refer To Note
On 10:1 Engines: Upper Compression Ring 0.030-0.070mm.
Lower Compression Ring 0.020-0.060mm. On 9:1 Engines: Upper
Compression Rings 0.020-0.060mm. Lower Compression Ring
0.020-0.060mm.
Piston Rings-Ring Gap-Compression (Top) 0.13-0.028 mm
Piston Rings-Ring Gap-Compression (Top) 0.15-0.30 mm
Ring Gap - Oil Ring (Steel Rail) 0.15-0.65 mm
Oil Ring-Side Clearance 0.027-0.196 mm
Piston Ring-Ring Gap-Compression-(Bottom) 0.30-0.55 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications > Page 1966
Piston Ring: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1975
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1976
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1977
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1978
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1979
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1980
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1981
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1982
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1983
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1984
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1985
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1986
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1987
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1988
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1989
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1990
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1991
6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1992
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1993
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1994
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1995
8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 1996
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm-Ratio 1.75 : 1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 2000
Rocker Arm Assembly: Service and Repair
Special Tools
ROLLER FOLLOWERS
Removal
1. Remove the valve cover.
2. Position the piston of the cylinder being repaired at the bottom of the stroke.
3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal
damage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 2001
4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller
followers.
Installation
1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C)
camshaft roller followers.
2. Remove the Valve Spring Spacer. 3. Install the valve cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Specifications
Valve Cover: Specifications
Valve Covers-Bolts Left 71-106 in.lb
Right 71-106 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Right Side
Valve Cover: Service and Repair Right Side
Removal
1. Raise the vehicle.
2. Disconnect the Crankshaft Position (CKP) Sensor electrical connector.
3. Disconnect the A/C compressor electrical connector. 4. Lower the vehicle. 5. Remove the
evaporator case. See: Heating and Air Conditioning/Evaporator Case/Service and Repair
6. Disconnect the A/C cycling switch connector. 7. Disconnect the fuel lines.
8. Disconnect the ignition coils electrical connectors.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Right Side > Page 2007
9. Disconnect the fuel injector electrical connectors.
10. Remove the positive crankcase ventilation tube and position out of the way.
11. Disconnect the electrical connector. 12. Remove the Evaporative Emission (EVAP) Canister
Purge Valve.
13. Reposition the hold-down clamp and remove the hose from the bypass tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Right Side > Page 2008
14. NOTE: The valve cover harness retaining studs positions 2, and 3 retain the fuel charging
wiring.
Disconnect the harness from the valve cover and position out of the way.
15. Disconnect the heater hoses from the heater core and position aside.
16. Remove the studs, the bolts and the valve cover.
Installation
1. Follow the removal procedure in reverse order.
Apply sealant in the locations shown; use Silicone Gasket and Sealant F7AZ-M54-EA or equivalent
meeting Ford specification WSK-M2G343-A4.
2. Tighten in the sequence shown.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Right Side > Page 2009
Valve Cover: Service and Repair Left Side
Removal
1. Raise and support the vehicle. 2. Disconnect the oil pressure sensor electrical connector.
3. Lower the vehicle. 4. Remove the brake booster assembly.
5. Disconnect the cylinder head temperature sensor jumper wire connector.
6. Remove the bolt and the two studs and position the bracket out of the way.
7. Disconnect the Camshaft Position (CMP) sensor electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Right Side > Page 2010
8. Disconnect the fuel charging wiring electrical connectors from the coils and the fuel injectors.
9. Remove the wiper and cowl.
10. Disconnect the:
^ forty-two pin connector.
^ the sixteen-pin connector.
^ transmission electrical connector.
11. Remove the six bolts and five studs and remove the valve cover.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Right Side > Page 2011
1. Follow the removal procedure in reverse order:
^ Apply sealant in the locations shown; use Silicone Gasket and Sealant F7AZ-19554-EA or
equivalent meeting Ford specification WSK-M2G343-A4.
^ Refill and check the engine oil level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications
Valve Guide: Specifications
Valve Guide Inner Diameter 7.015-7.044 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications > Page 2015
Valve Guide: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications > Page 2016
Valve Guide: Service and Repair
Valve-Guide Reaming
2.If the valve guide is not within specifications, ream the valve guide and install valve with an
oversize stem or remove the valve guide and install new valve guide
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Valve Seat Diameter (Intake) 1.9-2.1 mm
Valve Seat Diameter (Exhaust) 1.9-2.1 mm
Valve Seat Angle 45 deg
Valve Seat Runout (TIR) Max 0.025 mm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications > Page 2020
Valve Seat: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Specifications
Valve Spring: Specifications
Valve Springs-Compression Pressure Intake 633.3-701.3 N at 28.02 mm
Exhaust 633.3-701.3 N at 28.02 mm
Valve Spring-Free Length Intake 50.2 mm
Exhaust 50.2 mm
Valve Springs-Installed Height 39.7-40.3 mm
Valve Springs-installed Pressure Intake 272.1-306.1 N at 40.0 mm
Exhaust 272.1-306.1 N at 40.0 mm
Valve Springs-Installed Pressure Service Limit 3%Pressure Loss N at 28.02 mm
Valve Springs-Installed Pressure Out Of Square Limit 2.5 deg
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Specifications > Page 2024
Valve Spring: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Specifications > Page 2025
Valve Spring: Service and Repair
Special Tools
Removal
1. Remove the camshaft roller followers.
2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air
in the cylinder to hold both valves in position.
4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the
cylinder. If air pressure must be removed, support the valve prior to removal.
Use the Valve Spring Compressor to compress the valve springs.
5. Remove the (A) valve spring retainer keys, the (B) valve spring retainers, and the (C) valve
spring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Specifications > Page 2026
Installation
1. Position the valve spring and the valve spring retainers.
2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal
damage.
3. Use the Valve Spring Compressor to compress the valve spring. Install the valve spring retainer
keys. 4. Install the camshaft roller followers.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Specifications > Page 2027
Valve Spring: Tools and Equipment
Special Tools
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Valve StemTo Guide Clearance(Intake) (0.00078-0.00270) in
Valve Stem To Guide Clearance(Exhaust) (0.018-0.0037) in
Valve Head Diameter(Intake) 1.75 in
Valve Head Diameter(Exhaust) 1.34 in
Valve Head Diameter-Gauge Diameters (1.26-1.67) in
Valve Face Width 1.91-2.16
Valve Face Runout Limit 0.002 in
Valve Face Angle 45.5 deg
Valve Stem Diameter(STD)-Intake (0.2746-0.275) in
Valve Stem Diameter(STD)-Exhaust (0.2736-0.274) in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications > Page 2031
Valve: Testing and Inspection
For further information regarding this component, please refer to Engine; Service and Repair;
General Procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications > Page 2032
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications
Drive Belt: Specifications
Drive Belt Tension See Note
Newly Installed-Refers To The Condition Of The NEW Drive
Belt Before The Engine Has Made No More Than One Revolution
And Before The Belt Has Had A Chance To Stretch Or Seat
Into The Pulley Grooves
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications > Page 2037
Drive Belt: Diagrams
Part 1 Of 2
Part 2 Of 2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications > Page 2038
Drive Belt: Service and Repair
Removal
1. Rotate the tensioner clockwise and remove the drive belt.
Installation
1. CAUTION: Incorrect drive belt installation will cause drive belt failure.
NOTE: Make sure the drive belt is correctly installed on each pulley.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair
Drive Belt Tensioner: Service and Repair
Removal
1. Remove the drive belt.
2. Remove the:
1 bolts.
2 belt guide.
3 drive belt tensioner.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2046
Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2047
^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2048
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2049
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2050
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2051
Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2053
The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2054
g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2059
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Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2082
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2083
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2084
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2085
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2086
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2087
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2088
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2089
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2090
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2091
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2092
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2093
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2094
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2095
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2096
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2097
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2098
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2099
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2101
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2102
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2103
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2104
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2105
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2106
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2107
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2108
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2109
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2110
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2111
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2112
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2113
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2114
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2115
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2116
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2117
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2118
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2119
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2120
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2121
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2122
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2123
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2124
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2125
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2126
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2127
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2128
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2129
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2130
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2131
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2132
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2133
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2134
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2135
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2136
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2137
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2138
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
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CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2140
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness
Procedure > Page 2141
Engine Mount: Technical Service Bulletins Engine Mounts - Unsatisfactory for Severe Conditions
Article No. 01-1-1
01/22/01
ENGINE MOUNTS - REVISED ENGINE MOUNTS FOR SEVERE DUTY VEHICLES
FORD: 1998-2000 CROWN VICTORIA
LINCOLN: 1998-2000 TOWN CAR
MERCURY: 1998-2000 GRAND MARQUIS
This article is being republished in its entirety to update the model year coverage and part
numbers.
ISSUE The engine mounts on some vehicles may not exhibit satisfactory durability under severe
operating conditions that may be encountered by Police, Taxi or Limo/Livery vehicles such as
extended idling at high ambient temperatures. This may be caused by the extreme heat generated
by the engine under these conditions.
ACTION If service to the engine mounts is required, install new revised engine mounts which
incorporate a heat shield. For left side engine mount, use 1W7Z-6038-BA - right side engine
mount, use 1W7Z-6038-AA. Refer to the appropriate model/year Workshop Manual, Section
303-01 for replacement procedure.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-21-4 WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 497000, 499000, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 2142
Engine Mount: Specifications
Engine Mounts 39-53 ft.lb
Engine Support Insulator Bolts 15-22 ft.lb
Motor Mount To Crossmember 39-53 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > LH
Engine Mount: Service and Repair LH
Removal
1. Remove the oil level indicator tube. 2. Suitably support the engine.
3. Remove the three bolts.
4. Remove the three bolts.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > LH > Page 2145
Engine Mount: Service and Repair RH
Removal
1. Remove the starter. 2. Suitably support the engine.
3. Remove the three bolts.
4. Remove the three bolts.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications
Idler Pulley: Specifications
Belt Idler Pulley 15-22 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications > Page 2149
Idler Pulley: Service and Repair
Removal
1. Remove the drive belt.
2. Remove the (A) bolt and the (B) belt idler pulley.
Installation
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure 40-70 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Specifications
Engine Oil Dip Stick - Dip Stick Tube: Specifications
Oil Filler Dipstick Tube .........................................................................................................................
....................................................... 71-106 inch lbs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Specifications > Page 2157
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Removal
1. Remove the exhaust manifold.
2. Remove the oil level indicator tube.
^ Remove the bolt.
^ Remove the tube.
3. Inspect the O-ring.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications
Technical Service Bulletin # 02-1-9 Date: 020121
Engine Oil - Oil Recommendations/Applications
Article No. 02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30
MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002
ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002
FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER
1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002
LS 1998-2002 NAVIGATOR
MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999
TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001
MOUNTAINEER
This article is being republished in its entirety to update the vehicle models, engines and years
affected.
NOTE
PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A
COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB.
ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most
gasoline and flexible fueled vehicles.
ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the
recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to
improve fuel economy.
Testing has validated this viscosity grade can be used in many previous model year vehicles. It is
recommended ALL vehicles on the following Vehicle Application Listing be service with SAE
5W-20.
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002
Vehicles" chart are being filled with SAE 5W-20
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2162
motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
Exception 2002 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED.
REFER TO TSB 99-8-16.
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000
Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2163
^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 1997-2002 2.0L Escort/Tracer
^ 1998-2002 2.0L Escort ZX2
^ 2000-2002 2.0L Focus
^ 2001-2002 2.0L Escape
^ 1993-1997 2.3L Ranger
^ 1993-1994 2.3L Mustang
^ 1993-1994 2.3L Tempo/Topaz
^ 1998-2001 2.5L Ranger
^ 1995-2000 2.5L Contour/Mystique
^ 1999-2002 2.5L Cougar
^ 2001-2002 3.0L 4V Escape
^ 1996-2001 3.0L 4V Taurus/Sable
^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger,
^ Taurus/Sable (Flexible Fuel and Gas)
^ 1995-2000 3.0L (Vulcan) Windstar
^ 1993-1994 3.0L (Vulcan) Tempo/Topaz
^ 2000-2002 3.0L 4V Lincoln LS
^ 1995-2002 3.8L Windstar
^ 1993-1997 3.8L Taurus/Sable,
^ Thunderbird/Cougar, Continental
^ 1994-2002 3.8L Mustang
^ 2002-2002 3.9L 4V Lincoln LS
^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series
^ 1996-2002 4.6L 2V Mustang
^ 1992-2002 4.6L Crown Victoria/Grand Marquis
^ 1991-2002 4.6L Town Car
^ 1994-1997 4.6L 2V Thunderbird/Cougar
^ 1996-2002 4.6L 4V Mustang Cobra
^ 1995-2002 4.6L 4V Continental
^ 1993-1998 4.6L 4V Mark VIII
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2164
^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition
^ 1993-1999 4.9L E-Series, F-Series
^ 1993-1995 5.0L Mustang/Mustang Cobra
^ 1993-1993 5.0L Thunderbird/Cougar
^ 1997-2001 5.0L Explorer/Mountaineer
^ 1993-1996 5.0L E-Series, F-Series, Bronco
^ 2000-2002 5.4L Excursion
^ 1998-2002 5.4L 2V/4V Navigator
^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350
Chassis/RV/Cutaway
^ 1993-1997 5.8L F-Series, Bronco
^ 1993-1996 5.8L E-Series
^ 2000-2002 6.8L Excursion
^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway
^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome
^ 1993-1998 7.5L All Vehicles
NOTE
FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV.
NOTE
THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR
OIL
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2165
Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation
Article No. 99-8-16
05/03/99
MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR
LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999
CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI
1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER
DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999
VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999
NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford
gasoline-powered vehicle regardless of model year.
ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade
motor oil. Refer to the following text for further details.
Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past
depending on vehicle model and model year.
Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and
benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE
5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures.
SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30.
SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum
Institute (API) should be used for all service procedures requiring replacement of the motor oil.
PART NUMBER PART NAME
XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 401000, 490000, 499000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
Capacity ...............................................................................................................................................
................................................ 6.24L (6.6 Qt +/- 0.1)
NOTE: Listed capacities are approximate. Check fluid level after filling.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 2168
Engine Oil: Fluid Type Specifications
Engine Oil Type ...................................................................................................................................
............................................................... SAE 5W-20
NOTE: Refer to TSB# 02-1-9
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 2169
Engine Oil: Service Precautions
SAFETY PRECAUTIONS
WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer.
Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Do not put oily rags in pockets.
- Avoid contaminating clothes, particularly underpants, with oil.
- Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be
cleaned regularly.
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to help the removal of oil from the
skin.
- Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanolin replace the natural skin oils which have been removed.
- Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay.
- Where practicable, degrease components prior to handling.
- Where there is a risk of eye contact, eye protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash facility should be provided.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Specifications
Oil Filter Adapter: Specifications
Oil Filter Adapter Bolts .........................................................................................................................
............................................................ 15-22 ft. lbs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Locations > Non Trailer Tow and Police Option
Oil Filter Adapter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Locations > Non Trailer Tow and Police Option > Page 2175
Oil Filter Adapter: Locations Trailer Tow and Police Option
Oil Filter Adapter (Trailer Tow and Police Option)
Oil Filter Adapter (Trailer Tow and Police Option)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Removal
Oil Filter Adapter: Service and Repair Removal
1. Drain the cooling system.
2. Disconnect the lower radiator hose from the oil filter adapter. 3. Raise the vehicle. 4. Drain the
engine oil.
5. Remove the oil bypass filter.
6. Remove the oil pressure sensor.
1. Disconnect the connector. 2. Remove the oil pressure sensor.
7. NOTE: On vehicles equipped with an oil cooler adapter, separate the wiring harness from the
side of the oil filter adapter. On vehicles with a
standard oil filter adapter, remove the harness pushpin from the oil filter adapter.
Remove the oil filter adapter.
^ Remove the bolts.
^ Remove the oil filter adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Removal > Page 2178
Oil Filter Adapter: Service and Repair Installation
1. Clean the sealing surfaces.
2. Install a new gasket.
3. Install the oil filter adapter and tighten in the sequence shown.
4. Install the oil pressure sensor.
5. Connect the connector.
6. Install the oil bypass filter.
7. Lower the vehicle.
8. Fill the crankcase with clean Ford Super Premium SAE 5W30 Motor Oil or equivalent meeting
Ford specification.
9. Connect the lower radiator hose.
10. Fill and bleed the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Oil Pan Bolts Stage 1 18 in.lb
Stage 2 15 ft.lb
Stage 3 Rotate 60 Degrees
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2182
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2183
Oil Pan: Service and Repair
Removal
1. Remove the air cleaner outlet tube. 2. Remove the wiper arm and pivot shaft assembly. 3.
Remove the drive belt. 4. Remove the fan motor and shroud assembly. 5. Disconnect the fuel lines.
6. Remove the Exhaust Gas Recirculation (EGR) tube. 7. Remove the generator. 8. Remove the
blower motor speed control.
9. Remove the RH engine mount bolt.
10. Remote the two LH engine mount bolts.
11. Remove the four nuts and support the exhaust.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2184
12. Remove the bolt for the transmission line support bracket.
13. Loosen the nuts for the transmission mount. 14. Lower the vehicle.
15. NOTE: The RH motor mount has a second bolt accessed from the top.
Remove the bolt.
16. Using the special tool, raise the engine with a suitable floor crane.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2185
17. Using the special tool, support the engine. 18. Raise the vehicle.
19. Remove the oil pan bolts.
20. Position the oil pan aside and remove the bolts from the oil pickup tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2186
21. Remove the bolt from the oil pickup tube bracket.
22. Remove the O-ring and inspect. 23. Remove the oil pan and gasket from the vehicle through
the front.
Installation
1. Install the oil pan and gasket on the vehicle.
2. Install the O-ring, using a new one if necessary.
3. Position the oil pickup tube and tighten the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2187
4. Install and tighten the bolts.
5. Tighten the nuts.
6. Install and tighten the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2188
7. Reposition the exhaust and tighten the nuts.
8. Install and tighten the bolts.
9. Install and tighten the bolt.
10. Lower the vehicle.
11. Using the special tool, and a suitable floor crane, raise the engine and remove the special tool.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2189
12. Remove the special tool.
13. Tighten the bolt.
14. Remove the engine lift bracket. 15. Install the blower motor speed control. 16. Install the
generator. 17. Install the EGR tube. 18. Connect the fuel lines. 19. Install the air cleaner outlet
tube. 20. Install the wiper arm and pivot shaft assembly. 21. Install the drive belt. 22. Install the fan
motor and shroud assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure Switch <-->
[Oil Pressure Sender] > Component Information > Locations
Engine Oil Pressure Switch: Locations
1. Oil Pressure Sensor
2. Oil Pressure Sensor Connector
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure Switch <-->
[Oil Pressure Sender] > Component Information > Locations > Page 2193
Engine Oil Pressure Switch: Service and Repair
Removal
1. Remove the oil pressure sensor oil pressure sensor:
1 Disconnect the wire.
2 Remove the oil pressure sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Description and Operation
Oil Pressure Warning Lamp/Indicator: Description and Operation
The low oil pressure warning indicator illuminates when the oil pressure switch opens, indicating oil
pressure that is below the normal range.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure 40-70 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage
Technical Service Bulletin # 05N04 Date: 051214
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2209
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005.
FSA VIN LIST ACTIVATED? No.
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if
the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original
receipt.
SOLD VEHICLES
Owners with affected vehicles that exhibit the covered condition will be directed to dealers for
repairs. Owners who have paid for this repair within seven years of the warranty start date will also
be directed to dealers to submit for reimbursement. Repairs that were performed after December
16 2005 will not be eligible for a refund unless an emergency repair was needed and a Ford or
Lincoln Mercury dealer was not available.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2210
It is highly unlikely that you will encounter related damage while performing this repair but if a
related damage condition exists that you believe to be caused by the covered condition call the
Special Service Support Center to request approval prior to the repair of any related damage.
Components such as ignition coils engines alternators spark plugs and spark plug wires are
examples that are not covered by this program. Requests for approval after completion of the
repair will not be granted.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition call the Special Service Support Center.
OWNER REFUNDS
^ Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one
refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund
program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01
open on OASIS call the Special Service Support Center for prior approval.
^ Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was
performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was
made when a Ford Lincoln or Mercury dealer was not available.)
^ The repair must have been completed within 7 years of the warranty start date to be eligible for a
refund.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Related damage must be claimed on a repair line that is separate from the repair line on which
the FSA is claimed. (Requires prior approval)
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
(Requires prior approval)
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2211
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirements through normal
order processing channels.
RECALL PARTS ASSISTANCE
There are three methods to use for questions or assistance regarding recall parts:
^ Parts Support Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2212
^ E-mail
^ FAX Number
When contacting the Parts Support Center via phone FAX or E-mail for a question or concern
please provide:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA # : Customer Satisfaction Program 05N04
^ Include a VIN #
^ Part number that you have a question / concern with
DEALER PRICE
For latest prices refer to DOES II.
PARTS RETENTION AND RETURN
Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts
Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for
part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
Attachment III - Technical Information
OVERVIEW
This program involves either:
A) inspecting the intake manifold part number to determine if the owner is eligible for
reimbursement for a previous intake manifold replacement repair without a receipt, or
B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the
event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the
intake manifold must be replaced.
Proceed to the appropriate inspection procedure.
PART NUMBER INSPECTION
NOTE:
The part number is molded into the intake manifold and is located between two (2) runners on the
driver side of the manifold. No disassembly is required to view the part number except for removal
of the engine appearance cover, if equipped.
^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part
number will be found on the driver side of the manifold, beneath the throttle body intake tube.
^ On applications where the throttle body is pointing toward the right side of the vehicle, the part
number is still located on the driver side of the manifold.
1. Remove the engine appearance cover, if equipped.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2213
2. Locate the area on the intake manifold where the part number is to be found. See Figure 1.
3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number
prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension
to reach the affected area to wipe after spraying with cleaner.
Clean the area between the two (2) runners by first blowing any dirt or foreign material away using
compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or
equivalent, and using a shop towel, wipe the area clean.
4. Read and record the intake manifold part number.
^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for
a refund without a receipt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2214
^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund
without a receipt.
COOLANT LEAKAGE INSPECTION
1. NOTE: To properly inspect the intake manifold you must look down behind the alternator.
Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant
leakage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop
Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999
through 2002 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.
Owner Letter
Owner Letter not applicable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage
Technical Service Bulletin # 01M02 Date: 010301
Campaign - Intake Manifold Additional Warranty Coverage
01M02
OWNER NOTIFICATION PROGRAM
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles:
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Owner Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2219
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2220
Attachment I - Administrative Information
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through
2001 Model Year Crown Victoria Police Interceptor - Certain 1998 through 2001 Model Year Crown
Victoria with Taxi Prep Package - Certain 1998 through 2001 Lincoln Town Car Limousine and
Livery Prep Package
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
On an "M" program, the VIN number will remain in OASIS until the time limit of the program
expires.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter
(or after the date of the Owner Letter if an emergency repair was made away from the servicing
dealer.) Refer to ACESII manual for refund information.
Program Code: 01M02 Misc. Expense: REFUND Misc. Expense: ADMIN
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2221
Misc. Expense: 0.2 Hr.
Refer to ACESII manual for refund information.
RENTAL CARS
Rental vehicle coverage is not included under this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PLEASE NOTE:
The labor times in the above table reflect the latest corporate standards for determining labor
times. These times apply to Owner Notification Program 01M02 and are not retroactive to previous
repairs.
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels as noted.
DOR/COR NUMBER
DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline
(1-800-325-5621).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2222
DEALER PRICE
For latest prices, refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
NOTE:
To properly inspect the intake manifold you must look down behind the alternator.
1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant
seepage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop
Manual section 03-01 for 1996 through 1998 model year vehicles and section 303-01 for 1999
through 2001 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2223
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2224
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage
Intake Manifold: Customer Interest Intake Manifold - Cross-Over Channel Coolant Seepage
Article No. 02-2-2
02/04/02
^ COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES
EQUIPPED WITH 4.6L 2V ENGINE ONLY
^ ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER
FORD: 1996-1997 THUNDERBIRD 1996-2001 CROWN VICTORIA, MUSTANG 2002 EXPLORER
LINCOLN: 1996-2001 TOWN CAR
MERCURY: 1996-1997 COUGAR 1996-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage
condition. This may be caused by a crack in the Intake Manifold coolant crossover.
ACTION Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area
(Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install
parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01).
4.6L 2V INTAKE MANIFOLD
INSPECTION/REPLACEMENT
Refer to Figure 1 for inspection of coolant seepage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage >
Page 2230
If seepage is found, order one of the following Service Kits to repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage >
Page 2231
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 402000, 499000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage
Technical Service Bulletin # 05N04 Date: 051214
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2237
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005.
FSA VIN LIST ACTIVATED? No.
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if
the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original
receipt.
SOLD VEHICLES
Owners with affected vehicles that exhibit the covered condition will be directed to dealers for
repairs. Owners who have paid for this repair within seven years of the warranty start date will also
be directed to dealers to submit for reimbursement. Repairs that were performed after December
16 2005 will not be eligible for a refund unless an emergency repair was needed and a Ford or
Lincoln Mercury dealer was not available.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2238
It is highly unlikely that you will encounter related damage while performing this repair but if a
related damage condition exists that you believe to be caused by the covered condition call the
Special Service Support Center to request approval prior to the repair of any related damage.
Components such as ignition coils engines alternators spark plugs and spark plug wires are
examples that are not covered by this program. Requests for approval after completion of the
repair will not be granted.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition call the Special Service Support Center.
OWNER REFUNDS
^ Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one
refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund
program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01
open on OASIS call the Special Service Support Center for prior approval.
^ Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was
performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was
made when a Ford Lincoln or Mercury dealer was not available.)
^ The repair must have been completed within 7 years of the warranty start date to be eligible for a
refund.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Related damage must be claimed on a repair line that is separate from the repair line on which
the FSA is claimed. (Requires prior approval)
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
(Requires prior approval)
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2239
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirements through normal
order processing channels.
RECALL PARTS ASSISTANCE
There are three methods to use for questions or assistance regarding recall parts:
^ Parts Support Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2240
^ E-mail
^ FAX Number
When contacting the Parts Support Center via phone FAX or E-mail for a question or concern
please provide:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA # : Customer Satisfaction Program 05N04
^ Include a VIN #
^ Part number that you have a question / concern with
DEALER PRICE
For latest prices refer to DOES II.
PARTS RETENTION AND RETURN
Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts
Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for
part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
Attachment III - Technical Information
OVERVIEW
This program involves either:
A) inspecting the intake manifold part number to determine if the owner is eligible for
reimbursement for a previous intake manifold replacement repair without a receipt, or
B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the
event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the
intake manifold must be replaced.
Proceed to the appropriate inspection procedure.
PART NUMBER INSPECTION
NOTE:
The part number is molded into the intake manifold and is located between two (2) runners on the
driver side of the manifold. No disassembly is required to view the part number except for removal
of the engine appearance cover, if equipped.
^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part
number will be found on the driver side of the manifold, beneath the throttle body intake tube.
^ On applications where the throttle body is pointing toward the right side of the vehicle, the part
number is still located on the driver side of the manifold.
1. Remove the engine appearance cover, if equipped.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2241
2. Locate the area on the intake manifold where the part number is to be found. See Figure 1.
3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number
prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension
to reach the affected area to wipe after spraying with cleaner.
Clean the area between the two (2) runners by first blowing any dirt or foreign material away using
compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or
equivalent, and using a shop towel, wipe the area clean.
4. Read and record the intake manifold part number.
^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for
a refund without a receipt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2242
^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund
without a receipt.
COOLANT LEAKAGE INSPECTION
1. NOTE: To properly inspect the intake manifold you must look down behind the alternator.
Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant
leakage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop
Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999
through 2002 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.
Owner Letter
Owner Letter not applicable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over
Channel Coolant Seepage
Intake Manifold: All Technical Service Bulletins Intake Manifold - Cross-Over Channel Coolant
Seepage
Article No. 02-2-2
02/04/02
^ COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES
EQUIPPED WITH 4.6L 2V ENGINE ONLY
^ ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER
FORD: 1996-1997 THUNDERBIRD 1996-2001 CROWN VICTORIA, MUSTANG 2002 EXPLORER
LINCOLN: 1996-2001 TOWN CAR
MERCURY: 1996-1997 COUGAR 1996-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage
condition. This may be caused by a crack in the Intake Manifold coolant crossover.
ACTION Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area
(Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install
parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01).
4.6L 2V INTAKE MANIFOLD
INSPECTION/REPLACEMENT
Refer to Figure 1 for inspection of coolant seepage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over
Channel Coolant Seepage > Page 2247
If seepage is found, order one of the following Service Kits to repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over
Channel Coolant Seepage > Page 2248
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 402000, 499000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage
Technical Service Bulletin # 01M02 Date: 010301
Campaign - Intake Manifold Additional Warranty Coverage
01M02
OWNER NOTIFICATION PROGRAM
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles:
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Owner Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2253
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2254
Attachment I - Administrative Information
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through
2001 Model Year Crown Victoria Police Interceptor - Certain 1998 through 2001 Model Year Crown
Victoria with Taxi Prep Package - Certain 1998 through 2001 Lincoln Town Car Limousine and
Livery Prep Package
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
On an "M" program, the VIN number will remain in OASIS until the time limit of the program
expires.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter
(or after the date of the Owner Letter if an emergency repair was made away from the servicing
dealer.) Refer to ACESII manual for refund information.
Program Code: 01M02 Misc. Expense: REFUND Misc. Expense: ADMIN
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2255
Misc. Expense: 0.2 Hr.
Refer to ACESII manual for refund information.
RENTAL CARS
Rental vehicle coverage is not included under this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PLEASE NOTE:
The labor times in the above table reflect the latest corporate standards for determining labor
times. These times apply to Owner Notification Program 01M02 and are not retroactive to previous
repairs.
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels as noted.
DOR/COR NUMBER
DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline
(1-800-325-5621).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2256
DEALER PRICE
For latest prices, refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
NOTE:
To properly inspect the intake manifold you must look down behind the alternator.
1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant
seepage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop
Manual section 03-01 for 1996 through 1998 model year vehicles and section 303-01 for 1999
through 2001 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2257
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2258
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over
Channel Coolant Seepage
Intake Manifold: All Technical Service Bulletins Intake Manifold - Cross-Over Channel Coolant
Seepage
Article No. 02-2-2
02/04/02
^ COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES
EQUIPPED WITH 4.6L 2V ENGINE ONLY
^ ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER
FORD: 1996-1997 THUNDERBIRD 1996-2001 CROWN VICTORIA, MUSTANG 2002 EXPLORER
LINCOLN: 1996-2001 TOWN CAR
MERCURY: 1996-1997 COUGAR 1996-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage
condition. This may be caused by a crack in the Intake Manifold coolant crossover.
ACTION Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area
(Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install
parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01).
4.6L 2V INTAKE MANIFOLD
INSPECTION/REPLACEMENT
Refer to Figure 1 for inspection of coolant seepage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over
Channel Coolant Seepage > Page 2264
If seepage is found, order one of the following Service Kits to repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Over
Channel Coolant Seepage > Page 2265
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 402000, 499000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage
Technical Service Bulletin # 05N04 Date: 051214
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2271
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005.
FSA VIN LIST ACTIVATED? No.
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if
the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original
receipt.
SOLD VEHICLES
Owners with affected vehicles that exhibit the covered condition will be directed to dealers for
repairs. Owners who have paid for this repair within seven years of the warranty start date will also
be directed to dealers to submit for reimbursement. Repairs that were performed after December
16 2005 will not be eligible for a refund unless an emergency repair was needed and a Ford or
Lincoln Mercury dealer was not available.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2272
It is highly unlikely that you will encounter related damage while performing this repair but if a
related damage condition exists that you believe to be caused by the covered condition call the
Special Service Support Center to request approval prior to the repair of any related damage.
Components such as ignition coils engines alternators spark plugs and spark plug wires are
examples that are not covered by this program. Requests for approval after completion of the
repair will not be granted.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition call the Special Service Support Center.
OWNER REFUNDS
^ Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one
refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund
program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01
open on OASIS call the Special Service Support Center for prior approval.
^ Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was
performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was
made when a Ford Lincoln or Mercury dealer was not available.)
^ The repair must have been completed within 7 years of the warranty start date to be eligible for a
refund.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Related damage must be claimed on a repair line that is separate from the repair line on which
the FSA is claimed. (Requires prior approval)
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
(Requires prior approval)
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2273
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirements through normal
order processing channels.
RECALL PARTS ASSISTANCE
There are three methods to use for questions or assistance regarding recall parts:
^ Parts Support Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2274
^ E-mail
^ FAX Number
When contacting the Parts Support Center via phone FAX or E-mail for a question or concern
please provide:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA # : Customer Satisfaction Program 05N04
^ Include a VIN #
^ Part number that you have a question / concern with
DEALER PRICE
For latest prices refer to DOES II.
PARTS RETENTION AND RETURN
Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts
Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for
part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
Attachment III - Technical Information
OVERVIEW
This program involves either:
A) inspecting the intake manifold part number to determine if the owner is eligible for
reimbursement for a previous intake manifold replacement repair without a receipt, or
B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the
event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the
intake manifold must be replaced.
Proceed to the appropriate inspection procedure.
PART NUMBER INSPECTION
NOTE:
The part number is molded into the intake manifold and is located between two (2) runners on the
driver side of the manifold. No disassembly is required to view the part number except for removal
of the engine appearance cover, if equipped.
^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part
number will be found on the driver side of the manifold, beneath the throttle body intake tube.
^ On applications where the throttle body is pointing toward the right side of the vehicle, the part
number is still located on the driver side of the manifold.
1. Remove the engine appearance cover, if equipped.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2275
2. Locate the area on the intake manifold where the part number is to be found. See Figure 1.
3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number
prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension
to reach the affected area to wipe after spraying with cleaner.
Clean the area between the two (2) runners by first blowing any dirt or foreign material away using
compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or
equivalent, and using a shop towel, wipe the area clean.
4. Read and record the intake manifold part number.
^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for
a refund without a receipt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05 > Campaign - Intake Manifold
Extended Warranty Coverage > Page 2276
^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund
without a receipt.
COOLANT LEAKAGE INSPECTION
1. NOTE: To properly inspect the intake manifold you must look down behind the alternator.
Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant
leakage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop
Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999
through 2002 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.
Owner Letter
Owner Letter not applicable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage
Technical Service Bulletin # 01M02 Date: 010301
Campaign - Intake Manifold Additional Warranty Coverage
01M02
OWNER NOTIFICATION PROGRAM
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles:
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Owner Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2281
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2282
Attachment I - Administrative Information
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through
2001 Model Year Crown Victoria Police Interceptor - Certain 1998 through 2001 Model Year Crown
Victoria with Taxi Prep Package - Certain 1998 through 2001 Lincoln Town Car Limousine and
Livery Prep Package
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
On an "M" program, the VIN number will remain in OASIS until the time limit of the program
expires.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter
(or after the date of the Owner Letter if an emergency repair was made away from the servicing
dealer.) Refer to ACESII manual for refund information.
Program Code: 01M02 Misc. Expense: REFUND Misc. Expense: ADMIN
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2283
Misc. Expense: 0.2 Hr.
Refer to ACESII manual for refund information.
RENTAL CARS
Rental vehicle coverage is not included under this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PLEASE NOTE:
The labor times in the above table reflect the latest corporate standards for determining labor
times. These times apply to Owner Notification Program 01M02 and are not retroactive to previous
repairs.
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels as noted.
DOR/COR NUMBER
DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline
(1-800-325-5621).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2284
DEALER PRICE
For latest prices, refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
NOTE:
To properly inspect the intake manifold you must look down behind the alternator.
1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant
seepage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop
Manual section 03-01 for 1996 through 1998 model year vehicles and section 303-01 for 1999
through 2001 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2285
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01 > Campaign - Intake Manifold
Additional Warranty Coverage > Page 2286
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 2287
Intake Manifold: Specifications
Throttle Body Fasteners 71-106 in.lb
Fuel Injection Supply Manifold bolts 89 in.lb
Upper Generator Support Bracket 71-106 in.lb
Intake Manifold Bolts 15-22 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal
Intake Manifold: Service and Repair Removal
1. Remove the wiper arm and pivot shaft. 2. Remove the air cleaner outlet tube. 3. Disconnect the
fuel line.
4. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils and the
eight fuel injectors.
5. Disconnect the fuel charging wiring electrical connector from the fuel pressure sensor.
6. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor.
7. Disconnect the fuel charging wiring electrical connector from the engine coolant temperature
sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2290
8. Separate the isolation valve wiring lead from the upper generator support bracket and
disconnect.
9. Disconnect the generator battery cable.
10. Remove the power distribution box access cover.
11. Remove the nut and the wiring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2291
12. Disconnect the fuel charging wiring electrical connectors at the inner fender splash shield.
13. Disconnect the fuel charging wiring electrical connector from the A/C pressure transducer.
14. Disconnect the fuel charging wiring electrical connector from the cylinder head temperature
sensor jumper.
15. Disconnect the fuel charging wiring electrical connector from the camshaft position sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2292
16. Disconnect the fuel charging wiring electrical connector from the generator.
17. Disconnect the fuel charging wiring electrical connector from the throttle position sensor.
18. Disconnect the fuel charging wiring from the radio ignition interference capacitor.
19. Disconnect the fuel charging wiring from the EGR vacuum regulator solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2293
20. Disconnect the fuel charging wiring from the differential pressure feedback EGR.
21. Disconnect the fuel charging wiring from the idle air control valve.
22. Disconnect the throttle cable and the speed control actuator cable from the throttle body.
23. Remove the bolts and position the cables and bracket out of the way.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2294
24. Remove the bolts and position the fuel charging wiring out of the way. 25. Disconnect the fuel
lines.
26. Disconnect the hoses from the differential pressure feedback EGR.
27. Disconnect the vacuum line from the Exhaust Gas Recirculation (EGR) valve.
28. Disconnect the main chassis vacuum supply line from the throttle body adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2295
29. Disconnect the crankcase ventilation tube at two locations and remove from the vehicle.
30. Disconnect the vacuum line from the throttle body adapter.
31. Disconnect the vacuum lines from the EGR vacuum regulator solenoid.
32. Disconnect the EGR tube from the EGR valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2296
33. Remove the bolts from the isolation valve.
34. Remove the four bolts.
35. Remove the fuel injection supply manifold and the fuel injectors as an assembly.
36. Disconnect the heater water hose from the intake manifold.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2297
37. Disconnect the upper radiator hose from the water outlet adapter.
38. Remove the bolts and the eight ignition coils.
39. Remove the bolts and the upper generator support bracket.
40. Remove the bolts and the water outlet adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2298
41. Remove the water thermostat and the O-ring.
42. Remove the bolts.
43. Remove the intake manifold.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2299
44. Remove the intake manifold gaskets.
45. Clean the sealing surfaces.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2300
Intake Manifold: Service and Repair Installation
1. Install new intake manifold gaskets.
2. Install the intake manifold.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2301
3. Install the bolts and tighten in the sequence shown.
4. Install the water thermostat and a new O-ring.
5. Install the water outlet adapter and tighten the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2302
6. Install the upper generator support bracket and tighten the bolts.
7. Install the eight ignition coils and tighten the bolts.
8. Connect the upper radiator hose to the water outlet adapter.
9. Connect the heater water hose to the intake manifold.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2303
10. Install the fuel injectors and the fuel injection supply manifold as an assembly.
11. Install the four bolts.
12. Install the bolts in the isolation valve and tighten.
13. Connect the EGR tube to the EGR valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2304
14. Connect the vacuum lines to the EGR vacuum regulator solenoid.
15. Connect the vacuum lines to the throttle body adapter.
16. Install the crankcase ventilation tube and connect at two locations.
17. Connect the main chassis vacuum supply line to the throttle body adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2305
18. Connect the vacuum line to the EGR valve.
19. Connect the hoses to the differential pressure feedback EGR. 20. Connect the fuel line.
21. Reposition the fuel charging wiring and install the bolts.
22. Reposition the cables and the bracket and install the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2306
23. Connect the throttle cable and the speed control actuator cable to the throttle body.
24. Connect the fuel charging wiring to the idle air control valve.
25. Connect the fuel charging wiring to the differential pressure feedback EGR.
26. Connect the fuel charging wiring to the EGR vacuum regulator solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2307
27. Connect the fuel charging wiring to the radio ignition interference capacitor.
28. Connect the fuel charging wiring electrical connector to the throttle position sensor.
29. Connect the fuel charging wiring electrical connector to the generator.
30. Connect the fuel charging wiring electrical connector to the camshaft position sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2308
31. Connect the fuel charging wiring electrical connector to the cylinder head temperature sensor
jumper.
32. Connect the fuel charging wiring electrical connector to the A/C pressure transducer..
33. Connect the fuel charging wiring electrical connectors at the inner fender splash shield.
34. Reposition the wiring on the stud and tighten the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2309
35. Install the power distribution box access cover.
36. Connect the generator battery cable and tighten the nut.
37. Connect the isolation valve jumper to the fuel charging wiring electrical connector.
38. Connect the fuel charging wiring electrical connector to the engine coolant temperature sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Removal > Page 2310
39. Connect the fuel charging wiring electrical connector to the fuel temperature sensor.
40. Connect the fuel charging wiring electrical connector to the fuel pressure sensor.
41. Connect the fuel charging wiring electrical connectors to the eight ignitions coils and the eight
fuel injectors. 42. Install the wiper arm and pivot shaft. 43. Install the air cleaner outlet tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Description and Operation
Oil Pressure Warning Lamp/Indicator: Description and Operation
The low oil pressure warning indicator illuminates when the oil pressure switch opens, indicating oil
pressure that is below the normal range.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Special Tools
Special Tools
Special Tools
Removal
1. Remove the transmission.
2. Remove the flywheel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 2319
3. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear
oil seal slinger.
4. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear
main seal.
5. If the oil dye leak test reveals a leak behind the retainer, remove the eight bolts and the
crankcase rear oil seal retainer.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
NOTE: Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting
Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes,
whichever is longer, failure to follow this procedure can cause future oil leakage.
Clean and inspect the mating surface.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 2320
2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
NOTE: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant
must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or
equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil
leakage.
NOTE: The silicone must be applied on the groove along the retainer plate.
Apply silicone around the rear oil seal retainer sealing surface. Use Silicone Gasket and Sealant
F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.
3. Install the rear oil seal retainer and loosely install the eight bolts.
4. Tighten the eight rear oil seal retainer bolts in the sequence shown.
5. NOTE: Lubricate the inner lip of the rear crankshaft seal with Ford Super Premium SAE 5W30
Motor Oil XO-5W30-QSP or equivalent meeting
Ford specification WSS-M2C153-G.
Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear
main seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 2321
6. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer
and the Rear Crankshaft Seal Replacer to install
the rear main seal slinger.
8. Install the transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From
R/H Cylinder Head Gasket
Cylinder Head Gasket: Customer Interest Engine - Oil Leak From R/H Cylinder Head Gasket
Article No. 03-6-2
03/31/03
ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY"
GASKET AND CYLINDER HEAD KITS AVAILABILITY
FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150,
SUPER DUTY F SERIES 2000-2001 EXCURSION
LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR
MERCURY: 1999-2002 GRAND MARQUIS
Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line
coverage.
ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L
Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the
right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to
engine performance or durability. An oil leak may be caused by metal chip debris lodged between
the head gasket and the block, chip debris between the cylinder head and the head gasket, or by
damage to the cylinder head sealing surface that occurred during the manufacturing process.
ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of
the head gasket can be performed. If the head was damaged by chip contamination, the head
should be replaced. A revised "Service-Only" gasket is now released for both of these cases.
SERVICE INFORMATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From
R/H Cylinder Head Gasket > Page 2330
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From
R/H Cylinder Head Gasket > Page 2331
Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may
still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing
area does not follow the same sealing path as the original gasket. This area is surrounding the
High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the
passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure
2).
Required for service are:
^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from
Snap-On or as provided by Ford Motor Company)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From
R/H Cylinder Head Gasket > Page 2332
^ Motorcraft Silicone Gasket Remover (ZC-30)
^ Metal Surface Prep (ZC-31)
^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side)
with the new embossed area
The engine should be allowed to cool before removing the head or warpage may occur in deck
flatness.
The cylinder head and block decks should be cleaned before performing a flatness check. Dark
metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with
grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any
residual silicone RTV with ZC-30 and ZC-31 applied in sequence.
The Workshop Manual and Service Labor Time Standards have been recently updated for both
cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include
instructions to remove the engine prior to removing the cylinder head. Service Labor Time
Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle.
Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for
applicability.
Cylinder Head Kits include:
^ Complete Head assembly, with Cam and Valves
^ Head Bolts
^ Service Only Head Gasket
^ Both Intake Gaskets Exhaust Gasket
^ One Rocker Cover Gasket
^ One set of Exhaust Studs and Nuts
If it is found that only one head is leaking, it is not necessary to remove the other head Only repair
the side for which leakage occurs.
For detailed information on these subjects refer to previous articles on general cylinder head
gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and
straightedge procedures.
Parts Block
OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2
SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000,
402000, 403000, 490000, 497000, 499000
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil
Leak From R/H Cylinder Head Gasket
Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head
Gasket
Article No. 03-6-2
03/31/03
ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY"
GASKET AND CYLINDER HEAD KITS AVAILABILITY
FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150,
SUPER DUTY F SERIES 2000-2001 EXCURSION
LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR
MERCURY: 1999-2002 GRAND MARQUIS
Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line
coverage.
ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L
Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the
right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to
engine performance or durability. An oil leak may be caused by metal chip debris lodged between
the head gasket and the block, chip debris between the cylinder head and the head gasket, or by
damage to the cylinder head sealing surface that occurred during the manufacturing process.
ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of
the head gasket can be performed. If the head was damaged by chip contamination, the head
should be replaced. A revised "Service-Only" gasket is now released for both of these cases.
SERVICE INFORMATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil
Leak From R/H Cylinder Head Gasket > Page 2338
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil
Leak From R/H Cylinder Head Gasket > Page 2339
Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may
still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing
area does not follow the same sealing path as the original gasket. This area is surrounding the
High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the
passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure
2).
Required for service are:
^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from
Snap-On or as provided by Ford Motor Company)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-6-2 > Mar > 03 > Engine - Oil
Leak From R/H Cylinder Head Gasket > Page 2340
^ Motorcraft Silicone Gasket Remover (ZC-30)
^ Metal Surface Prep (ZC-31)
^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side)
with the new embossed area
The engine should be allowed to cool before removing the head or warpage may occur in deck
flatness.
The cylinder head and block decks should be cleaned before performing a flatness check. Dark
metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with
grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any
residual silicone RTV with ZC-30 and ZC-31 applied in sequence.
The Workshop Manual and Service Labor Time Standards have been recently updated for both
cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include
instructions to remove the engine prior to removing the cylinder head. Service Labor Time
Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle.
Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for
applicability.
Cylinder Head Kits include:
^ Complete Head assembly, with Cam and Valves
^ Head Bolts
^ Service Only Head Gasket
^ Both Intake Gaskets Exhaust Gasket
^ One Rocker Cover Gasket
^ One set of Exhaust Studs and Nuts
If it is found that only one head is leaking, it is not necessary to remove the other head Only repair
the side for which leakage occurs.
For detailed information on these subjects refer to previous articles on general cylinder head
gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and
straightedge procedures.
Parts Block
OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2
SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000,
402000, 403000, 490000, 497000, 499000
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-1-4 > Jan > 02 > Engine Head
Gasket - Approved Replacement Procedures
Technical Service Bulletin # 02-1-4 Date: 020121
Engine Head Gasket - Approved Replacement Procedures
Article No. 02-1-4
01/21/02
ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES
FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG,
TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E
SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002
BLACKWOOD
MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE
1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER
ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been
found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or
scratches and dents at the head to block mating surfaces.
ACTION Refer to the following Service Information for recommended gasket sealing surface
preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks
coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are
necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done
successfully utilizing leak detection methods such as a black light dye process.
SERVICE PROCEDURE
To sum up, a successful leak repair depends on:
^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures
^ Surface preparation and gasket installation using the approved tools, cleaners, and methods
^ Exercising CARE and CLEANLINESS during disassembly/assembly of components
^ Use of genuine Ford OEM replacement parts
^ Use of a Ford Remanufacturer
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 402000, 403000, 499000
Aluminum Cylinder Head - Removal From Engine
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-1-4 > Jan > 02 > Engine Head
Gasket - Approved Replacement Procedures > Page 2345
WARNING
ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH
EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE
ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF
THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT
AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A
BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH
SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE
BENCHTOP OR DAMAGE WILL OCCUR.
NOTE
SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD
BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS
THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL
ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN
HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE
HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN
PERIOD.
NOTE
IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF
THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR
HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR
THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE.
Place CLEAN shop towels over the cylinder block bores to prevent further contamination from
reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected
on the towel can fall on the engine if care is not exercised as it is removed.
Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other
impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or
the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively.
Contamination on these surfaces will cause leaks from "shimming" the head even under full head
bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak
path.
Inspection For Damage and Cleaning Procedure
The overall straightness of the cylinder head and block face is held within very tight specification.
Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary
equipment. Machining must meet manufacturer's specification on surface finish quality and be less
than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler
gauge. If the engine has been overheated the cylinder head may have been damaged or warped.
Re-surfacing will not correct this damage.
The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm).
There must not be any scratches or gouges present, especially those which track to another
sealing cavity or to the atmosphere.
Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion,
and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the
surface of any material, which could later interfere with the gasket's sealing ability.
WARNING
UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED
USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M
BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE
BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON
STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL
DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO
ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE
ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE
OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT
SOLVENT.
The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head
gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the
last torquing procedure either from the plant or a previous field repair. The new head bolt shanks
and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip
for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole.
The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt
particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and
cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out
the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces.
To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft
Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop
vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from
the block surface.
It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has
been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks.
The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid
contaminants. Any staining of the metal surface is considered normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-1-4 > Jan > 02 > Engine Head
Gasket - Approved Replacement Procedures > Page 2346
Machining of aluminum heads and blocks is an unacceptable field practice for quality control
purposes of flatness and surface finish standards. Removing material will also raise the risk of
internal reciprocating components striking each other, as well as changing the emissions
calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable.
Ford Remanufacturers are authorized to perform this procedure and have the necessary
equipment to put the specified surface finish on the head within original factory limits.
Installation Onto the Cylinder Block Surface
WARNING
ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION
CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE
FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE
COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE
COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL
THEREBY TRIPPING FAULT CODES IN THE PCM.
Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or
liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner,
F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was
removed successfully from the surrounding areas of the block to head face of the head and the
block.
Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the
gasket surfaces to scrape or bang against other engine parts. The head may pick up material along
the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring
that the head is fully square, seated, and resting on the block deck in a level condition, install new
"torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year
Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the
intervals specified. Failure to follow these instructions may result in a warped head, and damaged
head bolt threads.
Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench.
Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt
the integrity of the bolt head and give a false reading on the final torque value of the fastener.
Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for
the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was)
primed properly and is in a "ready to start" condition with all engine oil galleys having been charged
with oil.
WARNING
DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL
PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW
HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN
THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE
INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND
STEADILY MAINTAINED.
Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks
around the gasket joints of the head, front cover, and associated component parts. The vehicle
should be road tested within normal guidelines to raise the engine to operating temperature and
verify the repair is sound.
Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to
levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift
Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear
Downshift
Article No. 01-13-7
07/09/01
^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W
AUTOMATIC TRANSMISSION
^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1
DOWNSHIFT
FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES,
EXPEDITION, EXPLORER, F-150
LINCOLN: 1999-2001 TOWN CAR
MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER
ISSUE
Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during
the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most
2-1 downshifts. This may be caused by a Planet Support Spring that is out of position.
ACTION
Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly,
the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift,
causing the "clunk" noise. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
NOTE
THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH
HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS
PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES.
1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is
originating from the transmission during the 2-1 downshift event.
NOTE
IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH
THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF
THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED.
2. Raise and support vehicle. Refer to Workshop Manual Section 100-02.
3. Check for correct torque on the following chassis & drivetrain components:
^ Driveshaft to Pinion Flange fasteners
^ Upper and Lower Control Arm fasteners (car applications)
^ Rear Leaf Spring Fasteners (truck applications)
^ Rear Shock Absorber fasteners
^ Transmission Mount and Crossmember fasteners
4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not
corrected, continue to Step 5.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 2352
5. Remove the transmission from the vehicle and disassemble down to and including the Center
Support Retaining Ring. Refer to Workshop Manual section 307-01.
6. Note the position of the Planet Support Spring. Compare to the correct installation which is
illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the
transmission case. The other tang should be loaded against the Planetary Gear Support.
7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly.
If the spring is damaged, replace with part number F5AZ-7F277-AA.
8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that
will apply equal force across the spring. This will ensure the spring is installed squarely with the
tangs loading the Transmission Case on one side and the Planetary Gear Support on the other.
9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part
number F2VY-7A136-A.
10. Lower vehicle, refill fluid to correct level and verity repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 2353
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 2354
Operation/Description/Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7F277 07
OASIS CODES: 502000, 504000, 597997
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H
Cylinder Head Gasket
Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head
Gasket
Article No. 03-6-2
03/31/03
ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY"
GASKET AND CYLINDER HEAD KITS AVAILABILITY
FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150,
SUPER DUTY F SERIES 2000-2001 EXCURSION
LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR
MERCURY: 1999-2002 GRAND MARQUIS
Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line
coverage.
ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L
Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the
right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to
engine performance or durability. An oil leak may be caused by metal chip debris lodged between
the head gasket and the block, chip debris between the cylinder head and the head gasket, or by
damage to the cylinder head sealing surface that occurred during the manufacturing process.
ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of
the head gasket can be performed. If the head was damaged by chip contamination, the head
should be replaced. A revised "Service-Only" gasket is now released for both of these cases.
SERVICE INFORMATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H
Cylinder Head Gasket > Page 2364
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H
Cylinder Head Gasket > Page 2365
Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may
still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing
area does not follow the same sealing path as the original gasket. This area is surrounding the
High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the
passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure
2).
Required for service are:
^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from
Snap-On or as provided by Ford Motor Company)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H
Cylinder Head Gasket > Page 2366
^ Motorcraft Silicone Gasket Remover (ZC-30)
^ Metal Surface Prep (ZC-31)
^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side)
with the new embossed area
The engine should be allowed to cool before removing the head or warpage may occur in deck
flatness.
The cylinder head and block decks should be cleaned before performing a flatness check. Dark
metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with
grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any
residual silicone RTV with ZC-30 and ZC-31 applied in sequence.
The Workshop Manual and Service Labor Time Standards have been recently updated for both
cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include
instructions to remove the engine prior to removing the cylinder head. Service Labor Time
Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle.
Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for
applicability.
Cylinder Head Kits include:
^ Complete Head assembly, with Cam and Valves
^ Head Bolts
^ Service Only Head Gasket
^ Both Intake Gaskets Exhaust Gasket
^ One Rocker Cover Gasket
^ One set of Exhaust Studs and Nuts
If it is found that only one head is leaking, it is not necessary to remove the other head Only repair
the side for which leakage occurs.
For detailed information on these subjects refer to previous articles on general cylinder head
gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and
straightedge procedures.
Parts Block
OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2
SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000,
402000, 403000, 490000, 497000, 499000
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved
Replacement Procedures
Technical Service Bulletin # 02-1-4 Date: 020121
Engine Head Gasket - Approved Replacement Procedures
Article No. 02-1-4
01/21/02
ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES
FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG,
TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E
SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002
BLACKWOOD
MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE
1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER
ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been
found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or
scratches and dents at the head to block mating surfaces.
ACTION Refer to the following Service Information for recommended gasket sealing surface
preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks
coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are
necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done
successfully utilizing leak detection methods such as a black light dye process.
SERVICE PROCEDURE
To sum up, a successful leak repair depends on:
^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures
^ Surface preparation and gasket installation using the approved tools, cleaners, and methods
^ Exercising CARE and CLEANLINESS during disassembly/assembly of components
^ Use of genuine Ford OEM replacement parts
^ Use of a Ford Remanufacturer
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 402000, 403000, 499000
Aluminum Cylinder Head - Removal From Engine
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved
Replacement Procedures > Page 2371
WARNING
ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH
EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE
ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF
THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT
AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A
BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH
SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE
BENCHTOP OR DAMAGE WILL OCCUR.
NOTE
SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD
BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS
THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL
ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN
HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE
HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN
PERIOD.
NOTE
IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF
THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR
HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR
THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE.
Place CLEAN shop towels over the cylinder block bores to prevent further contamination from
reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected
on the towel can fall on the engine if care is not exercised as it is removed.
Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other
impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or
the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively.
Contamination on these surfaces will cause leaks from "shimming" the head even under full head
bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak
path.
Inspection For Damage and Cleaning Procedure
The overall straightness of the cylinder head and block face is held within very tight specification.
Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary
equipment. Machining must meet manufacturer's specification on surface finish quality and be less
than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler
gauge. If the engine has been overheated the cylinder head may have been damaged or warped.
Re-surfacing will not correct this damage.
The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm).
There must not be any scratches or gouges present, especially those which track to another
sealing cavity or to the atmosphere.
Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion,
and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the
surface of any material, which could later interfere with the gasket's sealing ability.
WARNING
UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED
USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M
BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE
BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON
STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL
DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO
ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE
ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE
OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT
SOLVENT.
The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head
gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the
last torquing procedure either from the plant or a previous field repair. The new head bolt shanks
and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip
for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole.
The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt
particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and
cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out
the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces.
To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft
Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop
vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from
the block surface.
It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has
been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks.
The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid
contaminants. Any staining of the metal surface is considered normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 01-13-7 >
Jul > 01 > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved
Replacement Procedures > Page 2372
Machining of aluminum heads and blocks is an unacceptable field practice for quality control
purposes of flatness and surface finish standards. Removing material will also raise the risk of
internal reciprocating components striking each other, as well as changing the emissions
calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable.
Ford Remanufacturers are authorized to perform this procedure and have the necessary
equipment to put the specified surface finish on the head within original factory limits.
Installation Onto the Cylinder Block Surface
WARNING
ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION
CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE
FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE
COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE
COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL
THEREBY TRIPPING FAULT CODES IN THE PCM.
Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or
liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner,
F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was
removed successfully from the surrounding areas of the block to head face of the head and the
block.
Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the
gasket surfaces to scrape or bang against other engine parts. The head may pick up material along
the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring
that the head is fully square, seated, and resting on the block deck in a level condition, install new
"torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year
Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the
intervals specified. Failure to follow these instructions may result in a warped head, and damaged
head bolt threads.
Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench.
Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt
the integrity of the bolt head and give a false reading on the final torque value of the fastener.
Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for
the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was)
primed properly and is in a "ready to start" condition with all engine oil galleys having been charged
with oil.
WARNING
DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL
PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW
HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN
THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE
INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND
STEADILY MAINTAINED.
Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks
around the gasket joints of the head, front cover, and associated component parts. The vehicle
should be road tested within normal guidelines to raise the engine to operating temperature and
verify the repair is sound.
Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to
levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Removal
1. Remove the crankshaft pulley.
2. Use the (A) Front Cover Seal Remover to remove the (B) front cover seal.
Installation
1. Lubricate the (A) engine front cover and the (B) front oil seal inner lip.
Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford
specification WSS-M2C153-G.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 2376
2. Use the (A) Crankshaft Seal Replacer/Cover Aligner to install the (B) crankshaft front seal into
the (C) engine front cover. 3. Install the crankshaft pulley.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Special Tools
Removal
1. Remove the valve springs.
2. Remove the valve stem seals.
Installation
1. NOTE: The valve stem seal must be bottomed on the valve seat.
NOTE: Make sure that the garter spring is present in the valve stem seal.
Use the (A) Valve Stem Seal Replacer to install the (B) valve stem seals.
2. Install the valve springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2380
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Engine Oil Pressure
Switch <--> [Oil Pressure Sender] > Component Information > Locations
Engine Oil Pressure Switch: Locations
1. Oil Pressure Sensor
2. Oil Pressure Sensor Connector
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Engine Oil Pressure
Switch <--> [Oil Pressure Sender] > Component Information > Locations > Page 2385
Engine Oil Pressure Switch: Service and Repair
Removal
1. Remove the oil pressure sensor oil pressure sensor:
1 Disconnect the wire.
2 Remove the oil pressure sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
TORQUE SPECIFICATIONS
Camshaft Sprocket Bolt
........................................................................................................................................................
110-130 Nm (81-95 Ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket >
Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Stage 1 66 ft.lb
Stage 2 Loosen 360 Degrees
Stage 3 35-39 ft.lb
Stage 4 Rotate 85-90 Degrees
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Removal
CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or
piston and valve damage may occur.
1. Remove the engine front cover. 2. Remove the roller followers.
3. Remove the (A) crankshaft sensor ring from the (B) crankshaft.
4. Rotate the crankshaft until both camshaft keyways are 90 degrees from the valve cover surface.
Make sure the copper links line up with the dots on
the camshaft sprocket.
5. Remove the (A) bolts and the (B) LH timing chain tensioner.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2396
6. Remove the (A) bolts and the (B) RH timing chain tensioner.
7. Remove the LH and RH timing chain tensioner arm from the dowel pins. 8. Remove the timing
chains and crankshaft sprockets from the camshafts and crankshaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2397
9. Remove the timing chain guide
1 Remove the bolts.
2 Remove the LH timing chain guide.
3 Remove the bolts.
4 Remove the RH timing chain guide.
Installation
1. CAUTION: The timing chain procedures must be followed exactly or damage to valves and
pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Compress the tensioner plunger, using an edge of a vise.
2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2398
3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and
plunger in during installation.
5. If the copper links are not visible, mark two links on one end and one link on the other end, and
use as timing marks.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2399
6. Install the timing chain guide.
1 Position LH timing chain guide.
2 Install and tighten the bolts.
3 Position the RH timing chain guide.
4 Install and tighten the RH bolts.
7. Install the timing chain and the crankshaft sprockets.
1 Slide the (A) crankshaft main bearing thrust washer onto the (B) crankshaft, aligning the copper
link on the timing chain with the dot on the crankshaft main bearing thrust washer.
2 Position the timing chain over the camshaft sprocket, aligning the copper link with the dot on the
camshaft sprocket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2400
8. Make sure that the (A) copper marks on the timing chain/belt are lined up with the corresponding
dots on the crankshaft sprockets and the
camshaft sprockets.
9. Make sure that the (A) camshaft sprocket keyway is 90 degrees from the (B) valve cover
mounting surface.
Fig. 26 Crankshaft Sprocket Position
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2401
10. Make sure that the (A) RH crankshaft sprocket is on the front of the (B) LH crankshaft sprocket
with the long hubs facing each other.
11. Position the LH and RH timing chain tensioner arms on the dowel pins.
12. Position the RH timing chain tensioner and install the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 2402
13. Position the LH timing chain tensioner and install the bolts.
14. Remove both the RH and LH retaining pins from the timing chain tensioner.
15. Install the (A) crankshaft sensor ring on the (B) crankshaft sprocket. 16. Install the engine front
cover. 17. Install the roller followers.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide >
Component Information > Specifications
Timing Chain Guide: Specifications
LH Timing Chain Guide Bolts 71-106 in.lb
RH Timing Chain Guide Bolts 71-106 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide >
Component Information > Specifications > Page 2406
Timing Chain Guide: Service and Repair
Refer to Timing Chain; Service and Repair for service of timing drive components.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Timing Chain Tensioners 18 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications > Page 2410
Timing Chain Tensioner: Service and Repair
Refer to Timing Chain; Service and Repair for service of timing drive components.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Engine Front Cover Bolts Stage 1: Tighten Fasteners 1-7 15-22 in.lb
Stage 2: Tighten Fasteners 6-15 30-41 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2414
Timing Cover: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Remove both valve covers. 3. Remove the water pump.
4. Raise and support the vehicle.
5. Remove the bolts and position the power steering pump aside.
6. Remove the oil pan drain plug and drain the engine oil.
7. Remove the bolts. 8. Lower the vehicle. 9. Remove the crankshaft front seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2415
10. Remove the bolt and the belt idler pulley.
11. Remove the bolts and stud bolts.
12. Remove the engine front cover from the front-cover-to-cylinder-block dowel.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2416
1. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed
and the sealing area cleaned with Metal Surface
Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry
until there is no sign of wetness, or for four minutes, whichever is longer. Failure to follow this
procedure can cause future oil leakage.
Apply silicone along the cylinder head-to-block surface and the oil pan-to-cylinder block surface.
Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification
WSK-M2G343-A4.
2. Install the engine front cover on the front-cover-to-cylinder-block dowel and loosely install the
bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2417
3. Tighten the front cover bolts and stud bolts in sequence in two stages.
Stage 1: Tighten fasteners 1 through 7 to 20-30 Nm ( 15 -22 ft. lbs.). Stage 2: Tighten fasteners 6
through 15 to 40-55 Nm (29-40 ft. lbs.).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2418
4. Position the belt idler pulley and install the bolt.
5. Install a new engine front cover front oil seal. 6. Raise and support the vehicle.
7. Loosely install the front oil pan bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2419
8. NOTE: Make sure to tighten the bolts in two stages.
Tighten the bolts in the sequence shown in two stages.
1 Tighten to 20 Nm (15 ft. lbs.).
2 Tighten an additional 60 degrees.
9. NOTE: The front lower hole in the power steering pump is not used.
Position the power steering pump and install the bolts.
10. Install the oil pan drain plug. 11. Lower the vehicle. 12. Install the valve covers. 13. Install the
water pump. 14. Connect the battery ground cable. 15. Fill the engine with oil.
Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford
specification WSS-M2C153-G.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Pressure
Fuel Pressure: Specifications Fuel Pressure
Fuel Pressure
Fuel Rail Pressure 105 - 130 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Pressure > Page 2425
Fuel Pressure: Specifications Volume
Flow .....................................................................................................................................................
................................................................. 160 lbs/hr
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications Idle Speed
Idle Speed
Hot Idle 790-815 rpm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
REMOVAL
1. On gasoline vehicles, remove the engine appearance cover.
^ Loosen the retainer.
^ Remove the cover.
2. Remove the idle air control valve inlet tube.
3. Remove the crankcase ventilation hose.
4. Loosen the clamps and remove the air cleaner outlet tube.
NOTE: Gasoline shown, natural gas similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2433
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
1. Release the metal clips.
2. Lift the cover.
3. Remove the Air Cleaner (ACL) element.
INSTALLATION
1. To install,reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2442
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2443
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2444
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2445
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2446
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2447
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2448
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2449
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2450
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2451
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2452
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2453
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2454
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2455
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2456
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2457
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2458
6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2459
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2460
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2461
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2462
8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures >
Page 2463
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap > Page 2475
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2476
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
............................................................... AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2477
Spark Plug: Description and Operation
The spark plugs:
^ change a high voltage pulse into a spark which ignites the fuel and air mixture.
^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2478
Spark Plug: Service and Repair
REMOVAL
1. Remove the ignition coil.
2. Remove the spark plugs.
NOTE: Use compressed air to remove any debris from the spark plug well before removing the
spark plugs.
3. Inspect the spark plugs for a gap bridged.
^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
4. Inspect for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2479
5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips,
exposed shell surfaces and electrodes. This is caused
by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive
idling. ^
Clean the spark plug.
6. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
7. Inspect for pre-ignition,
^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the
insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of
fuel or the installation of a heli-coil insert in place of the spark plug threads.
^ Install a new spark plug.
8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown
spots with bluish-burnt appearance of
electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs,
spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2480
^ Install a new spark plug.
9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or
blisters. These are caused by sudden acceleration.
^ Clean the spark plug.
10. Adjust the spark plug gap as required.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2484
Compression Check: Testing and Inspection
Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the
battery is properly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons
in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating improperly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2485
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Water Pump 15-22 ft.lb
Water Pump Pulley 15-22 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2492
Water Pump: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Drain the coolant.
2. Loosen the bolts. 3. Remove the belt.
4. Remove the bolts and the water pump pulley.
5. Remove the four bolts from the water pump.
6. Remove the water pump.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2493
7. Clean water pump mounting surface.
Installation
1. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the
O-ring can occur, causing the water pump
to leak.
NOTE: Install a new O-ring seal and lubricate with Ford Premium Engine Coolant E2FZ-19549-AA,
F5FZ-19549-CC in Oregon, CXC-10 in Canada or equivalent meeting Ford Specification
ESE-M97B44-A.
To install, reverse the removal procedure.
2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations
Article No. 01-23-6
11/26/01
^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON
ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION
ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR
2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO
1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002
EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F
SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER
SPORT 2000-2002 F-650, F-750
LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD
MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE
1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002
VILLAGER 1997-2002 MOUNTAINEER
MERKUR: 1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUE This TSB article describes Ford Motor Company's position on the use of propylene
glycol-based engine coolants.
ACTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2499
Ford Motor Company does not recommend nor endorse the use of engine coolants made with
propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene
glycol-based engine coolants.
Published information suggests that engine coolants made with propylene glycol may provide
engine cooling performance equivalent to engine coolants made with ethylene glycol. However,
different brands of engine coolant provide varying corrosion protection for the cooling system. Ford
does not have performance data for the multitude of engine coolants available in the aftermarket
and therefore cannot recommend the use of any coolant except those sold by Ford Customer
Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer
Service Division coolant for the vehicle.
Furthermore, claims of toxicological and environmental advantages of propylene glycol over
ethylene glycol may be misleading. When significant new information is developed, Ford will review
this policy.
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene
glycol-based engine coolants. Those specifications do not refer to engine coolants made with
propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon
the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its
components, the cost of repairing the damage would not be covered by the Ford New Vehicle
Limited Warranty.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Engine Cooling System 15 L
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 2502
Coolant: Fluid Type Specifications
Coolant Type .......................................................................................................................................
................................ Ford Premium Engine Coolant
Ford Specification.................................................................................................................................
.........................................................ESE-M97B44-A
Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe
Engine Coolant (orange in color).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Page 2503
Coolant: Service Precautions
DO NOT mix green colored coolant with orange colored coolant.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block >
Component Information > Specifications
Coolant Drain Plug: Specifications
Cylinder Block Drain Plug 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications
Coolant Reservoir: Specifications
Degas Bottle Bolts ...............................................................................................................................
............................................. 8-12 Nm (71-106 lb in)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications > Page 2510
Coolant Reservoir: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. NOTE: Drain coolant from the degas bottle only. Remove the degas bottle supply hose.
2. Remove the overflow hose.
3. Remove the bolt and the degas bottle.
Installation
1. Follow the removal procedure in reverse order. 2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM Engine Spark Knock While Accelerating > Page 2520
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM Engine Spark Knock While Accelerating > Page 2521
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Control Module: > 02-9-7 > May > 02 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May >
00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Control Module: > 02-9-7 > May > 02 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May >
00 > PCM - Engine Spark Knock While Accelerating > Page 2531
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Control Module: > 02-9-7 > May > 02 > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May >
00 > PCM - Engine Spark Knock While Accelerating > Page 2532
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Control Module: > Page 2533
Clutch: Specifications
Clearance 0.062 - 0.85 in
Snap Ring Thickness 0.050 - 0.054
0.064 - 0.068
0.078 - 0.082
0.092 - 0.096
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May
> 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May
> 00 > PCM - Engine Spark Knock While Accelerating > Page 2542
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May
> 00 > PCM - Engine Spark Knock While Accelerating > Page 2543
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure
Technical Service Bulletin # 03-2-6 Date: 030203
Cooling System - Cooling Fan Motor Service Procedure
Article No. 03-2-6
03/02/03
^ ELECTRICAL - REVISED COOLING FAN MOTOR AVAILABLE
^ COOLING - REVISED COOLING FAN MOTOR AVAILABLE
FORD: 1998-2000 CROWN VICTORIA
MERCURY: 1998-2000 GRAND MARQUIS
Article 03-1-1 is being republished in its entirety to update the artwork figures.
ISSUE When necessary to service the cooling tan assembly motor, service 1998-2000 model with
later model cooling fan assembly motor and a wiring pigtail for compatibility.
ACTION Use cooling fan assembly 1W7Z-8C607-AA to service Crown Victoria/Grand Marquis
vehicles built 1998 Job 1 through April 4, 2000. Pigtail Connector F8AZ-14370-AA is required for
compatibility. Follow Service Procedure.
Parts Block
OTHER APPLICABLE ARTICLES: 01-10-12 SUPERSEDES:03-1-1 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage. Also Under the Provisions Of
Emissions Warranty Coverage For 2000 Model Year Only
OPERATION DESCRIPTION TIME
030206A Replace Engine Cooling 0.9 Hr.
Fan And Install New Wiring Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
8C607 42
OASIS CODES: 402000
Disclaimer
Service Procedure
For 1998 - 2000 Model Year Vehicles Built Before April 4, 2000
1. Disconnect battery ground cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2549
2. Disconnect fan motor electrical connector.
3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan
shroud.
4. Remove the bolt and position aside degas bottle.
NOTE
THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE
A SECOND PERSON TO HOLD THE DEGAS BOTTLE OUT OF THE WAY.
5. Remove (2) bolts and remove fan and shroud assembly.
6. Install lower radiator hose support bracket onto new fan shroud.
7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m).
8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m).
9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig
tail, then remove wires from the convolute.
10. Cut the existing connector from the engine compartment wiring harness make each cut an inch
and a half from the previous cut so that after splicing the wires can be reinstalled into the
convolute.
11. Splice the three wires in the pigtail to the engine compartment harness as follows:
a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1).
b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2550
c. Splay the strands of the cut wires (Figure 2).
d. Twist/mesh the strands of the two wires together (Figure 3).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2551
e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4).
f. Repeat previous step.
g. Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and
solder flows completely into the strands. Use rosin core mildly activated (RMA) solder. DO NOT
use acid core solder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2552
h. Center the heat shrink tubing on the splice (Figure 6).
i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of
the tubing (Figure 7).
12. Install and tape spliced wires back into convolute.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2553
13. Connect fan motor, position back tower hose onto support bracket, and install wire harness
pushpin onto new fan shroud using the lowest locating hole (Figure 8).
14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m).
15. Verify fan operation with NGS/WDS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2558
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Cooling Fan: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2559
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure
Technical Service Bulletin # 03-2-6 Date: 030203
Cooling System - Cooling Fan Motor Service Procedure
Article No. 03-2-6
03/02/03
^ ELECTRICAL - REVISED COOLING FAN MOTOR AVAILABLE
^ COOLING - REVISED COOLING FAN MOTOR AVAILABLE
FORD: 1998-2000 CROWN VICTORIA
MERCURY: 1998-2000 GRAND MARQUIS
Article 03-1-1 is being republished in its entirety to update the artwork figures.
ISSUE When necessary to service the cooling tan assembly motor, service 1998-2000 model with
later model cooling fan assembly motor and a wiring pigtail for compatibility.
ACTION Use cooling fan assembly 1W7Z-8C607-AA to service Crown Victoria/Grand Marquis
vehicles built 1998 Job 1 through April 4, 2000. Pigtail Connector F8AZ-14370-AA is required for
compatibility. Follow Service Procedure.
Parts Block
OTHER APPLICABLE ARTICLES: 01-10-12 SUPERSEDES:03-1-1 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage. Also Under the Provisions Of
Emissions Warranty Coverage For 2000 Model Year Only
OPERATION DESCRIPTION TIME
030206A Replace Engine Cooling 0.9 Hr.
Fan And Install New Wiring Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
8C607 42
OASIS CODES: 402000
Disclaimer
Service Procedure
For 1998 - 2000 Model Year Vehicles Built Before April 4, 2000
1. Disconnect battery ground cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2565
2. Disconnect fan motor electrical connector.
3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan
shroud.
4. Remove the bolt and position aside degas bottle.
NOTE
THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE
A SECOND PERSON TO HOLD THE DEGAS BOTTLE OUT OF THE WAY.
5. Remove (2) bolts and remove fan and shroud assembly.
6. Install lower radiator hose support bracket onto new fan shroud.
7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m).
8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m).
9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig
tail, then remove wires from the convolute.
10. Cut the existing connector from the engine compartment wiring harness make each cut an inch
and a half from the previous cut so that after splicing the wires can be reinstalled into the
convolute.
11. Splice the three wires in the pigtail to the engine compartment harness as follows:
a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1).
b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2566
c. Splay the strands of the cut wires (Figure 2).
d. Twist/mesh the strands of the two wires together (Figure 3).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2567
e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4).
f. Repeat previous step.
g. Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and
solder flows completely into the strands. Use rosin core mildly activated (RMA) solder. DO NOT
use acid core solder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2568
h. Center the heat shrink tubing on the splice (Figure 6).
i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of
the tubing (Figure 7).
12. Install and tape spliced wires back into convolute.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Cooling Fan: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2569
13. Connect fan motor, position back tower hose onto support bracket, and install wire harness
pushpin onto new fan shroud using the lowest locating hole (Figure 8).
14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m).
15. Verify fan operation with NGS/WDS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Cooling Fan <-->
[Radiator Cooling Fan Motor] > Component Information > Technical Service Bulletins > Page 2570
Cooling Fan: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Remove the degas bottle.
2. Disconnect the connector.
3. Remove the two bolts and the fan blade, fan motor and the fan shroud assembly.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor Relay > Component Information > Locations > Page 2574
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Temperature Sensor / Switch > Component Information > Description and Operation
Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation
NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor
provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant
Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling
fans.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation
Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation
NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor
provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant
Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling
fans.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Specifications > Page 2588
Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Service and Repair
Engine Coolant Temperature Sender: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Partially drain the engine cooling system.
2. Remove the water temperature indicator sender unit.
1 Disconnect the electrical connector.
2 Remove the water temperature indicator sender unit.
Installation
1. Install the water temperature indicator sender unit.
1 Install the water temperature indicator sender unit.
2 Connect the electrical connector.
2. Fill the engine cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications
Fan Shroud: Specifications
Fan Shroud Screws 45-61 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2603
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2604
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2610
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2611
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 2612
Heater Core: Specifications
Rubber Suspension Insulator Lube E25Y-19553-A
....................................................................................................................................
ESF-M99B112-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 2613
Heater Core: Description and Operation
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 2614
Heater Core: Testing and Inspection
WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate
the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to
vent the exhaust gases outside the closed area. Failure to follow these instructions may result in
personal injury.
1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good
and a new heater core was not required. 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.
2. Check the integrity of the heater water hose clamps.
NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at the heater water hose connection and damage the
heater core.
Heater Core-Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is working
correctly.
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, feel the heater core outlet hose
to see if it is hot.
If it is not hot:
- the heater core may have an air pocket.
- the heater core may be plugged.
- the thermostat may not be working correctly.
Heater Core-Pressure Test
Use the Radiator/Heater Core Pressure Tester to carry out the pressure test.
1. Drain the coolant from the cooling system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and
heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the
radiator/heater core pressure
tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose
clamps.
5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the
pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater
water hoses do not leak, remove the heater
core from the vehicle and carry out the bench test.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 2615
Heater Core-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 inch) test heater water hoses with plug and adapter to the core tubes.
Then connect the radiator/heater core pressure tester
to the adapter.
4. Apply 241 kPa (35 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.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Back Flushing-Heater Core
Heater Core: Service and Repair Back Flushing-Heater Core
Special Tools
1. WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these
instructions can result in damage to the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas bottle when removing the pressure
relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly. Step back while the pressure is released from the cooling system. when you are
sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap.
Once pressure is released, remove the pressure relief cap.
2. Partially drain the cooling system.
3. NOTE: Refer to the cooling system Flush-All Operating Instructions for particular vehicle
hook-up.
Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to backflush the heater
core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification
ESR-M14P7A for vehicles filled with Premium Engine Coolant E2FZ-19549-AA or equivalent
meeting Ford specification ESE-M97B44-A (green color). Use warm water for vehicles filled with
Extended Life Engine Coolant F6AZ-19544-AA or equivalent meeting Ford specification
WSS-M97B44-D or DEX-COOL (orange color).
4. Fill the cooling system. See: Service and Repair
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Back Flushing-Heater Core > Page 2618
Heater Core: Service and Repair Removal and Installation
REMOVAL
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
1. Remove the plenum chamber. See: Heating and Air Conditioning/Heater Air Plenum
Chamber/Service and Repair
2. Remove the screws and the heater core cover.
3. Carefully cut the seal above the heater core inlet and outlet tubes and remove the heater core.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Page 2619
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2628
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2629
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2635
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 2636
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Page 2637
Heater Hose: Service and Repair
REMOVAL
1. Drain the radiator.
2. Remove the heater hoses from the heater core.
3. Remove the heater hoses from the engine.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or
equivalent meeting Ford specification ESF-M99B112-A.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Description and Operation
Temperature Gauge: Description and Operation
The engine coolant temperature gauge indicates the engine coolant temperature based on the
operating resistance range from the engine coolant temperature sender. If the engine coolant
temperature is low, the sender resistance is high. If the engine coolant temperature is high, the
sender resistance is low. The engine coolant temperature sender resistance range should be
between 9.7 ohms and 74 ohms.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Specifications
Radiator: Specifications
Radiator Bracket Bolts 80 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Specifications > Page 2645
Radiator: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Raise the vehicle. 2. Drain the engine cooling system. 3. Remove the fan blade, fan motor and
fan shroud assembly.
4. Release three hold downs and remove radiator sight shield.
5. Remove the upper radiator hose from the radiator.
6. Remove the lower radiator hose from the radiator.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Specifications > Page 2646
7. Remove the bolts and the radiator supports.
8. Remove the bolts and position the A/C condenser core and the transmission oil cooler away
from the radiator.
9. Remove the radiator.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Specifications > Page 2647
1. Follow the removal procedure in reverse order.
2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Specifications
Radiator Cap: Specifications
Pressure Relief Cap Opening Pressure 16 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Service and Repair
Radiator Hose: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Raise the vehicle. 2. Drain the coolant.
3. Remove the lower radiator hose from the radiator.
4. Remove the lower radiator hoses from the oil cooler; (with engine oil cooler). 5. Lower the
vehicle.
6. Remove the lower radiator hose from the degas bottle.
7. Remove the lower radiator hose from the oil filter adapter assembly and remove the lower
radiator hoses from the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Service and Repair > Page 2654
Installation
1. NOTE: Position clamps properly.
Follow the removal procedure in reverse order.
2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2664
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2665
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating >
Page 2671
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating >
Page 2672
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2676
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Description and Operation
Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation
NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor
provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant
Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling
fans.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications >
Page 2688
Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] >
Component Information > Service and Repair
Engine Coolant Temperature Sender: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Partially drain the engine cooling system.
2. Remove the water temperature indicator sender unit.
1 Disconnect the electrical connector.
2 Remove the water temperature indicator sender unit.
Installation
1. Install the water temperature indicator sender unit.
1 Install the water temperature indicator sender unit.
2 Connect the electrical connector.
2. Fill the engine cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Description and Operation
Temperature Gauge: Description and Operation
The engine coolant temperature gauge indicates the engine coolant temperature based on the
operating resistance range from the engine coolant temperature sender. If the engine coolant
temperature is low, the sender resistance is high. If the engine coolant temperature is high, the
sender resistance is low. The engine coolant temperature sender resistance range should be
between 9.7 ohms and 74 ohms.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Water Thermostat-Start To Open Temperature 192-199 Degrees F
Water Thermostat-Full Open Temperature 219 Degrees F
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2698
Thermostat: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Drain coolant below water thermostat.
2. Remove the screw and cover.
3. Remove the bolts from the water hose connection.
4. Position the water hose connection and the upper radiator hose out of the way.
5. Remove the water thermostat and the O-ring from the intake manifold.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2699
1. Follow the removal procedure in reverse order. 2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Specifications
Thermostat Housing: Specifications
Water Outlet Adapter 15-22 ft.lb
Water Bypass Tube Stud 15-22 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump 15-22 ft.lb
Water Pump Pulley 15-22 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2706
Water Pump: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Drain the coolant.
2. Loosen the bolts. 3. Remove the belt.
4. Remove the bolts and the water pump pulley.
5. Remove the four bolts from the water pump.
6. Remove the water pump.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2707
7. Clean water pump mounting surface.
Installation
1. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the
O-ring can occur, causing the water pump
to leak.
NOTE: Install a new O-ring seal and lubricate with Ford Premium Engine Coolant E2FZ-19549-AA,
F5FZ-19549-CC in Oregon, CXC-10 in Canada or equivalent meeting Ford Specification
ESE-M97B44-A.
To install, reverse the removal procedure.
2. Fill the cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low
Power
Catalytic Converter: Customer Interest CNG Fuel System - Hard Start/DTC's Set/Low Power
Article No. 03-20-6
10/13/03
^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND
5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L
ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150
ISSUE
Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector
performance, resulting from fuel quality. The conditions (in approximate order of their occurrence)
include:
^ Loss Of Power At Heavy Load
^ DTC Codes For Lean Fuel
^ Rough Idle
^ Hard Start
^ Plugged Catalytic Converter
^ No Start
NOTE
THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE
DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER.
ACTION The root cause of these conditions may be due to either excessive or insufficient
carryover compressor oil from the CNG fill station.
Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of
10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous
fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the
injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the
injector is opened, but may delay opening or prevent an injector from opening at all. The deposit
may increase over time and may further delay the injector opening time. Insufficient oil (less than
10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to
open the injector, especially when cold. In either case, the customer may first notice a loss of
power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel
logic adjustment range for injector pulse width is exceeded.
Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector
partially or completely shut and cause a hard start or no start. A hard start and temporary rough
idle when cold is caused by some of the injectors being marginally functional at the start, and the
other injectors becoming functional as they warm up from. engine heat and soften the oil deposit
enough to release the stuck pintle.
A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely
to form injector deposits than either type alone. Vehicles that fill from many stations are more likely
to exhibit the conditions. The oil type may also change if a station compressor is serviced or
replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly
evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has
collected in a tank can still remain available to mix even after the compressor oil has been
changed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low
Power > Page 2717
SERVICE PROCEDURE
Different actions are required according to the cause and severity of the conditions exhibited. The
actions to correct an insufficient oil situation are different than the actions to correct an excessive
oil situation.
Customers reporting the conditions listed above may determine their situation by some quick
checks on the vehicle.
EVIDENCE OF INSUFFICIENT OIL INCLUDES:
^ No oil film on fill station nozzle outlet or vehicle fill receptacle.
^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl.
^ A dry coalescing filter element.
EVIDENCE OF EXCESSIVE OIL INCLUDES:
^ Heavy oil film on station nozzle outlet and vehicle fill receptacle.
^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the
element.
^ Fully oil-soaked coalescing element.
^ Liquid oil found in fuel tanks or lines opened for other service.
Fill stations that derive compressed natural gas from liquefied natural gas should have an oil
injection system. The extremely cold temperature of liquefied natural gas literally "freezes out"
lubricants and these lubricants need to be replaced after the gas returns to its vapor phase.
Customers operating their own fill stations (usually fleet customers) should routinely check that all
installed equipment is operating properly and is serviced at the intervals recommended by the
component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate
filters, and coalescing filters. A fill station may have many filters at different points in the flow
stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet,
and the dispenser. A particulate filter that becomes clogged will indicate its condition by high
differential pressures or reduced total flow. A coalescing filter that is not drained often enough can
fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream
components with no obvious indication at the filter. A fill station technician draining a pressurized
coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble,
again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than
normal due to poor sealing at the piston rings. A fill station maintenance routine should include
recording the oil volume drained from downstream filters. This record can be used to compare the
oil volume added to the compressor. This will reveal compressor wear and the associated
maintenance requirements due to this wear.
Customers who maintain their own vehicles should consider measuring and recording the oil level
found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in
several vehicles in a short period of time may indicate that a fueling station used by those vehicles
requires service to reduce its compressor oil carryover.
Fleet customers should inquire about the maintenance practices of the fill stations they use.
For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty
Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter
bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil
in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in
the fuel does not affect the filter element life, so the element should be replaced at the normal
30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil.
It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush
Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel
injectors to return to their normal function. In some fuel environments it may be necessary to
perform this cleaning on a regular basis.
NOTE
IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE
APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3
FOR THE INJECTOR CLEANING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's Set/Low
Power > Page 2718
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel
System - Hard Start/DTC's Set/Low Power
Catalytic Converter: All Technical Service Bulletins CNG Fuel System - Hard Start/DTC's Set/Low
Power
Article No. 03-20-6
10/13/03
^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND
5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L
ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150
ISSUE
Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector
performance, resulting from fuel quality. The conditions (in approximate order of their occurrence)
include:
^ Loss Of Power At Heavy Load
^ DTC Codes For Lean Fuel
^ Rough Idle
^ Hard Start
^ Plugged Catalytic Converter
^ No Start
NOTE
THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE
DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER.
ACTION The root cause of these conditions may be due to either excessive or insufficient
carryover compressor oil from the CNG fill station.
Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of
10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous
fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the
injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the
injector is opened, but may delay opening or prevent an injector from opening at all. The deposit
may increase over time and may further delay the injector opening time. Insufficient oil (less than
10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to
open the injector, especially when cold. In either case, the customer may first notice a loss of
power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel
logic adjustment range for injector pulse width is exceeded.
Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector
partially or completely shut and cause a hard start or no start. A hard start and temporary rough
idle when cold is caused by some of the injectors being marginally functional at the start, and the
other injectors becoming functional as they warm up from. engine heat and soften the oil deposit
enough to release the stuck pintle.
A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely
to form injector deposits than either type alone. Vehicles that fill from many stations are more likely
to exhibit the conditions. The oil type may also change if a station compressor is serviced or
replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly
evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has
collected in a tank can still remain available to mix even after the compressor oil has been
changed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel
System - Hard Start/DTC's Set/Low Power > Page 2724
SERVICE PROCEDURE
Different actions are required according to the cause and severity of the conditions exhibited. The
actions to correct an insufficient oil situation are different than the actions to correct an excessive
oil situation.
Customers reporting the conditions listed above may determine their situation by some quick
checks on the vehicle.
EVIDENCE OF INSUFFICIENT OIL INCLUDES:
^ No oil film on fill station nozzle outlet or vehicle fill receptacle.
^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl.
^ A dry coalescing filter element.
EVIDENCE OF EXCESSIVE OIL INCLUDES:
^ Heavy oil film on station nozzle outlet and vehicle fill receptacle.
^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the
element.
^ Fully oil-soaked coalescing element.
^ Liquid oil found in fuel tanks or lines opened for other service.
Fill stations that derive compressed natural gas from liquefied natural gas should have an oil
injection system. The extremely cold temperature of liquefied natural gas literally "freezes out"
lubricants and these lubricants need to be replaced after the gas returns to its vapor phase.
Customers operating their own fill stations (usually fleet customers) should routinely check that all
installed equipment is operating properly and is serviced at the intervals recommended by the
component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate
filters, and coalescing filters. A fill station may have many filters at different points in the flow
stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet,
and the dispenser. A particulate filter that becomes clogged will indicate its condition by high
differential pressures or reduced total flow. A coalescing filter that is not drained often enough can
fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream
components with no obvious indication at the filter. A fill station technician draining a pressurized
coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble,
again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than
normal due to poor sealing at the piston rings. A fill station maintenance routine should include
recording the oil volume drained from downstream filters. This record can be used to compare the
oil volume added to the compressor. This will reveal compressor wear and the associated
maintenance requirements due to this wear.
Customers who maintain their own vehicles should consider measuring and recording the oil level
found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in
several vehicles in a short period of time may indicate that a fueling station used by those vehicles
requires service to reduce its compressor oil carryover.
Fleet customers should inquire about the maintenance practices of the fill stations they use.
For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty
Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter
bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil
in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in
the fuel does not affect the filter element life, so the element should be replaced at the normal
30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil.
It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush
Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel
injectors to return to their normal function. In some fuel environments it may be necessary to
perform this cleaning on a regular basis.
NOTE
IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE
APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3
FOR THE INJECTOR CLEANING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 > CNG Fuel
System - Hard Start/DTC's Set/Low Power > Page 2725
Disclaimer
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2730
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2731
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2732
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2733
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2734
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2735
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2736
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2737
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 2738
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine
Controls - Driveability Diagnosis > Page 2761
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine
Controls - Driveability Diagnosis > Page 2762
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine
Controls - Driveability Diagnosis > Page 2763
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 > Emissions/Engine
Controls - Driveability Diagnosis > Page 2764
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 2765
Catalytic Converter: Locations
Exhaust System
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 2766
Exhaust System
Dual Exhaust Catalyst Configuration
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 2767
Exhaust System
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 2768
Exhaust System
Single Exhaust Catalyst Configuration
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 2769
Catalytic Converter: Service and Repair
Removal
1. Raise and support the vehicle.
2. Disconnect the oxygen sensor connectors.
3. Remove the two nuts.
4. Remove the Three Way Catalytic Converter (TWC).
^ Remove the nuts, bolts, damper and gasket.
^ Remove the TWC.
Installation
1. Position the three way catalytic converters and install the two nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 2770
2. Install a new gasket, bolts, nuts and damper. 3. Connect the heated oxygen sensor connectors.
4. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Nuts 23-27 Nm (17-20 ft.lb)
LH Sequence ---
RH Sequence ---
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications > Page 2774
Exhaust Manifold: Testing and Inspection
1. Place a Straightedge across the exhaust manifold flanges and check for warping with a feeler
gauge.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Left Side
Exhaust Manifold: Service and Repair Left Side
Removal
1. Raise the vehicle. 2. Separate the exhaust at the exhaust manifold.
3. Remove the eight nuts.
4. Remove the exhaust manifold and the gasket.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Left Side > Page 2777
Exhaust Manifold: Service and Repair Right Side
Removal
1. Raise the vehicle. 2. Separate the exhaust at the exhaust manifold. 3. Disconnect the exhaust
gas recirculation tube at the exhaust manifold connector.
4. Remove the eight nuts.
^ Remove the exhaust manifold.
^ Remove the gasket.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Page 2778
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair
Exhaust Pipe: Service and Repair
For service and repair refer to Muffler; Service and Repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the inlet pipe-to-muffler clamp.
^ Remove the clamp nuts.
^ Remove the clamp.
3. NOTE: It may be necessary to heat the inlet pipe-to-muffler joint to ease removal.
NOTE: To remove the production muffler and tail pipe assembly, it will be necessary to cut the pipe
at a point over the axle. Cut the tailpipe at a point over the axle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2785
4. Remove the tailpipe assembly.
^ Remove the tailpipe from the exhaust hanger insulator.
^ Remove the tailpipe.
Installation
1. NOTE: It may be necessary to heat the inlet-to-muffler joint to ease installation.
Position the muffler and tailpipe assembly.
2. CAUTION: Do not use oil or grease-based lubricants on insulators which deteriorates the rubber.
NOTE: A soap-and-water solution will ease installation of the muffler hangers into the rubber
tailpipe hanger insulators.
Install the exhaust hanger insulators.
3. Install the tailpipe into the exhaust hanger insulator.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2786
4. Install the muffler to the inlet pipe.
^ Position the clamp.
^ Install the nuts.
5. Install the muffler-to-tailpipe gasket, nuts, and the bolts. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2794
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2795
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2796
Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle
Article No. 99-4-3
03/08/99
REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V
VEHICLES ONLY
FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97
PROBE 1996-99 CONTOUR, ESCORT, TAURUS
LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN
CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR
LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER,
WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99
EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to update the affected vehicles and to include an
Application Chart for the affected vehicles.
ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket
service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain
reasonably priced, timely PCM programming services at dealerships. Ford has released an
out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are
reprogrammable to update calibration levels or to reprogram a common hardware type to a new
calibration in order to fill a service need without ordering a new PCM.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2797
ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to
handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may
allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to
have modules updated to new calibrations through the Parts Department instead of ordering new
parts.
Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the
module. An aftermarket service center may bring a module to a dealership for a calibration update
or may request an updated calibration be installed to a new service part. The EPA regulations
require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash
Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a
calibration on a PCM out of the vehicle.
The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector.
The proper calibration must be downloaded to the Data Transfer Card through Service Bay
Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is
connected, follow the calibration download instructions displayed on the NGS screen.
The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling
1-800-ROTUNDA.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-26-3
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 203000, 206000, 290000, 690000, 698298
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 2798
Powertrain Control Module: Specifications
Powertrain Control Module Electrical Connector Bolt 4-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Powertrain Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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Powertrain Control Module: Connector Views
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Powertrain Control Module: Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
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Service and Repair > Procedures
Powertrain Control Module: Procedures
Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit
(IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration
information specific to the vehicle.
The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire
contents. This is usually due to either an after production strategy change or the Vehicle
Identification (VID) area has been previously reprogrammed and has reached its limit. The VID
block area can be tailored to accommodate various hardware changes made to the vehicle since
production. The VID block is a section of memory within the IC which includes items such as
octane adjust, fuel octane, fuel type, tire size and axle ratio.
Programming a Replacement PCM
A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from
the original PCM before removing from the vehicle. Refer to the flash VID block update procedure.
After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM
config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary
to manually reprogram the VID block. The scan tool is used to perform this procedure and is done
through the "PCM Programming" selection as described by the flash EEPROM procedure below.
Follow screen instructions.
Flash EEPROM Procedure
When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The
Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto
the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash
cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM
Programming" or refer to the flash instruction manual provided in the kit. VID block information can
also be viewed and changed during this procedure.
Flash VID Block Procedure
When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS
flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select
"Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module
Installation". The screen will now display two selections. The first is for old PCM information to be
retrieved and stored within the NGS. The second is for restoring the new PCM with information
which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement
instruction sheet included with the Ford Service Function card. Next, either a transfer of data from
the old module to the new module or a manual update must be performed on the VID block. Follow
screen instructions or refer to the supplement instruction sheet included with the Ford Service
Function card. If the VID block has been reprogrammed previously, the scan tool will display a
message. This message will indicate the need to reflash the entire IC.
NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer.
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Powertrain Control Module: Reset Procedure
Purpose for Clearing Codes
Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning
contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset.
After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will
be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and
performance.
A Keep Alive Random Access Memory Reset is done as follows:
During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is
found in the Active Command Modes menu on the New Generation Star scan tool.
If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's
instruction manual.
If an error message is received or the scan tool does not support this function, disconnecting the
battery ground cable for a minimum of 5 minutes may be used as an alternative procedure.
Powertrain Control Module (PCM/KAM Reset)
All OBDII scan tools support the Powertrain Control Module (PCM) reset.
The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic
information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II
system monitors or components have been tested to satisfy a drive cycle, without any other faults
occurring.
The following events occur when a PCM reset is performed:
- Clears the number of Diagnostic Trouble Codes (DTCs).
- Clears the DTCs.
- Clears the freeze frame data.
- Clears diagnostic monitoring test results.
- Resets status of the OBD II system monitors.
- Sets DTC P1000.
NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the
CLEAR button. This function is performed only after retrieval of continuous DTCs.
New Generation Star and Generic Scan Tool
Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM
reset.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Procedures > Page 2820
Powertrain Control Module: Removal and Replacement
Compressed Natural Gas Vehicle (NGV) Module
REMOVAL
WARNING
- DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
- IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service and Repair > Procedures > Page 2821
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
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1. To install, reverse the removal procedure.
- Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Gasoline
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the screw and position the powertrain control module electrical connector out of the
way.
3. Remove the nuts.
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4. Remove the powertrain control module cover.
5. Remove the three pin-type retainers and the under dash sight cover.
6. Remove the Powertrain Control Module (PCM).
INSTALLATION
1. To install, reverse the removal procedure.
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Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Page 2827
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
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Page 2828
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams >
Page 2829
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams >
Page 2830
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > PCM Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > PCM Power Relay > Page 2836
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams >
Page 2841
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams >
Page 2842
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams >
Page 2843
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams >
Page 2844
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page
2848
Fuel Valve Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page
2849
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > PCM Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > PCM Power Relay > Page 2855
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations
The ignition control module is integrated within the powertrain control module. It is not a separately
replaceable component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2860
Ignition Control Module: Description and Operation
PURPOSE
- The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM).
The ICM receives engine position and speed information from within the crankshaft position sensor
and desired spark advance information from the PCM.
OPERATION
- The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use
within The PCM.
- The PCM uses this information to determine which ignition coil to fire, calculating the turn
ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 2871
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 2872
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 2878
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 2879
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Page 2880
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Page 2881
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Page 2882
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Technical Service Bulletins > Page 2883
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
2887
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 2894
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 2895
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Page 2896
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications >
Page 2900
Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications
Fuel Tank Pressure Sensor: Specifications
Fuel Tank Pressure Sensor 55 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications >
Page 2904
Fuel Tank Pressure Sensor: Service and Repair
NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs.
REMOVAL
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the NGV fuel tank pressure sensor.
1 Disconnect the NGV fuel tank pressure sensor electrical connector.
2 Remove the NGV fuel tank pressure sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy.
^ Replace the NGV fuel tank pressure sensor O-ring seal.
^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil
XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to
help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2908
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2913
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2914
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2915
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2916
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2917
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2918
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2919
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2920
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2921
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 2922
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Emissions/Engine Controls - Driveability Diagnosis > Page 2923
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Page 2928
Oxygen Sensor: Specifications
Heated Oxygen Sensor - Front (HO2S) 36-46 Nm
Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm
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H02S Location
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front
Oxygen Sensor: Service and Repair Front
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S).
3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and
support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
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Page 2947
5. Remove the front heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford
specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation.
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Oxygen Sensor: Service and Repair Rear
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S).
4. Remove the rear heated oxygen sensor.
INSTALLATION
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1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford
specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
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Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
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Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
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Specifications > Page 2955
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 2962
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 2963
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Specifications > Page 2964
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
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Specifications > Page 2965
Special Tools
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Information and Instructions > Page 2971
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Information and Instructions > Page 2972
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2973
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2974
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Information and Instructions > Page 2975
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Information and Instructions > Page 2977
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Information and Instructions > Page 2978
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information and Instructions > Page 2981
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2982
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2983
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 2988
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Specifications > Page 2989
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Specifications > Page 2990
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
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Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
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Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3000
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
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Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3001
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
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Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
> Page 3007
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
> Page 3008
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow Sensor: > 02-17-6 > Sep > 02 > A/T - Inadvertent
Shift Interlock Disabling
High Mounted Stop Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow Sensor: > 02-17-6 > Sep > 02 > A/T - Inadvertent
Shift Interlock Disabling > Page 3014
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow Sensor: > 02-17-6 > Sep > 02 > A/T - Inadvertent
Shift Interlock Disabling > Page 3020
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3021
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3022
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3023
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3024
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications
Fuel Temperature Sensor: Specifications
Fuel Tank Temperature Sensor 40 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair >
Fuel Tank Temperature (Upper) Sensor
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor
REMOVAL
NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.1.
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the upper NGV fuel tank temperature sensor.
1 Disconnect the electrical connector.
2 Remove the fuel tank temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair >
Fuel Tank Temperature (Upper) Sensor > Page 3030
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor
REMOVAL
NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.2.
1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle.
3. Remove the lower NGV fuel tank shield upper nuts.
4. Remove the lower NGV fuel tank shield.
1 Remove the nuts.
2 Remove the lower NGV fuel tank shield.
5. Remove the lower NGV fuel tank temperature sensor.
1 Disconnect the lower NGV fuel tank temperature sensor electrical connector.
2 Remove the lower NGV fuel tank temperature sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair >
Fuel Tank Temperature (Upper) Sensor > Page 3031
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy
^ Replace the lower NGV fuel tank temperature sensor O-ring seal.
^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30
engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to
installation, to help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3040
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3041
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3042
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3043
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3044
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3045
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3046
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3047
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3048
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 3049
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3055
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3056
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3057
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3058
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3059
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3060
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3061
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3062
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3063
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 3064
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Page 3065
Inertia Fuel Shutoff Switch: Specifications
Inertia Fuel Shutoff Switch Screws
............................................................................................................................................................
1.0 Nm (9 in lbs)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service
Bulletins > Page 3066
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Open the luggage compartment door.
3. Disconnect the connector from the inertia fuel shutoff switch.
4. Remove the retaining screws from the inertia fuel shutoff switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3074
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3078
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3079
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3080
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available
Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 3086
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 3087
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 3088
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 3089
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Locks - Lock Service Packages Available > Page 3090
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 3091
Ignition Switch Lock Cylinder: Specifications
Lock Cylinder Housing Screws ............................................................................................................
.................................................... 22 Nm (16 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional
Ignition Switch Lock Cylinder: Service and Repair Functional
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional > Page 3094
Ignition Switch Lock Cylinder: Service and Repair Non-Functional
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional > Page 3095
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the steering column lock housing bearing and steering column lock gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
1. Install the steering column lock gear and bearing.
^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification
ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing
bearing.
^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three
o'clock position. Rotate it counterclockwise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Functional > Page 3096
2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install
the steering wheel.
4. Install the ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3100
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Pressure
Fuel Pressure: Specifications Fuel Pressure
Fuel Pressure
Fuel Rail Pressure 105 - 130 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Pressure > Page 3106
Fuel Pressure: Specifications Volume
Flow .....................................................................................................................................................
................................................................. 160 lbs/hr
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications Idle Speed
Idle Speed
Hot Idle 790-815 rpm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
REMOVAL
1. On gasoline vehicles, remove the engine appearance cover.
^ Loosen the retainer.
^ Remove the cover.
2. Remove the idle air control valve inlet tube.
3. Remove the crankcase ventilation hose.
4. Loosen the clamps and remove the air cleaner outlet tube.
NOTE: Gasoline shown, natural gas similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3114
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
1. Release the metal clips.
2. Lift the cover.
3. Remove the Air Cleaner (ACL) element.
INSTALLATION
1. To install,reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3123
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3124
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3125
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3126
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3127
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
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3128
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3129
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3130
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3131
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3132
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3133
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3134
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3135
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3136
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
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18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3138
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3140
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
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3141
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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3142
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Special Tools Used While Performing Procedures > Page
3144
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap > Page 3156
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3157
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
............................................................... AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3158
Spark Plug: Description and Operation
The spark plugs:
^ change a high voltage pulse into a spark which ignites the fuel and air mixture.
^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3159
Spark Plug: Service and Repair
REMOVAL
1. Remove the ignition coil.
2. Remove the spark plugs.
NOTE: Use compressed air to remove any debris from the spark plug well before removing the
spark plugs.
3. Inspect the spark plugs for a gap bridged.
^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
4. Inspect for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3160
5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips,
exposed shell surfaces and electrodes. This is caused
by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive
idling. ^
Clean the spark plug.
6. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
7. Inspect for pre-ignition,
^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the
insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of
fuel or the installation of a heli-coil insert in place of the spark plug threads.
^ Install a new spark plug.
8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown
spots with bluish-burnt appearance of
electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs,
spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3161
^ Install a new spark plug.
9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or
blisters. These are caused by sudden acceleration.
^ Clean the spark plug.
10. Adjust the spark plug gap as required.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 3165
Compression Check: Testing and Inspection
Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the
battery is properly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Pressure Limit Chart (Part 1 Of 2)
Compression Pressure Limit Chart (Part 2 Of 2)
Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons
in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating improperly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 3166
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does
not require adjustment.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: >
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: >
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3179
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: >
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3180
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air
Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air
Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3186
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air
Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3187
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3188
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3189
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3190
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3191
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 3195
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 3202
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 3203
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 3204
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3209
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3210
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3211
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3212
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3213
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3214
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3215
Data Link Connector: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Component Information > Diagrams > Diagram Information and Instructions > Page 3216
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3219
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3220
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3221
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3222
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures > Page 3227
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures > Page 3228
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures > Page 3229
Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle
Article No. 99-4-3
03/08/99
REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V
VEHICLES ONLY
FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97
PROBE 1996-99 CONTOUR, ESCORT, TAURUS
LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN
CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR
LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER,
WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99
EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to update the affected vehicles and to include an
Application Chart for the affected vehicles.
ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket
service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain
reasonably priced, timely PCM programming services at dealerships. Ford has released an
out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are
reprogrammable to update calibration levels or to reprogram a common hardware type to a new
calibration in order to fill a service need without ordering a new PCM.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures > Page 3230
ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to
handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may
allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to
have modules updated to new calibrations through the Parts Department instead of ordering new
parts.
Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the
module. An aftermarket service center may bring a module to a dealership for a calibration update
or may request an updated calibration be installed to a new service part. The EPA regulations
require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash
Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a
calibration on a PCM out of the vehicle.
The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector.
The proper calibration must be downloaded to the Data Transfer Card through Service Bay
Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is
connected, follow the calibration download instructions displayed on the NGS screen.
The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling
1-800-ROTUNDA.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-26-3
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 203000, 206000, 290000, 690000, 698298
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[Engine Control Module] > Component Information > Technical Service Bulletins > Page 3231
Powertrain Control Module: Specifications
Powertrain Control Module Electrical Connector Bolt 4-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3234
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3235
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Powertrain Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3246
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3247
Powertrain Control Module: Connector Views
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[Engine Control Module] > Component Information > Diagrams > Page 3249
Powertrain Control Module: Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
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[Engine Control Module] > Component Information > Service and Repair > Procedures
Powertrain Control Module: Procedures
Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit
(IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration
information specific to the vehicle.
The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire
contents. This is usually due to either an after production strategy change or the Vehicle
Identification (VID) area has been previously reprogrammed and has reached its limit. The VID
block area can be tailored to accommodate various hardware changes made to the vehicle since
production. The VID block is a section of memory within the IC which includes items such as
octane adjust, fuel octane, fuel type, tire size and axle ratio.
Programming a Replacement PCM
A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from
the original PCM before removing from the vehicle. Refer to the flash VID block update procedure.
After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM
config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary
to manually reprogram the VID block. The scan tool is used to perform this procedure and is done
through the "PCM Programming" selection as described by the flash EEPROM procedure below.
Follow screen instructions.
Flash EEPROM Procedure
When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The
Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto
the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash
cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM
Programming" or refer to the flash instruction manual provided in the kit. VID block information can
also be viewed and changed during this procedure.
Flash VID Block Procedure
When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS
flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select
"Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module
Installation". The screen will now display two selections. The first is for old PCM information to be
retrieved and stored within the NGS. The second is for restoring the new PCM with information
which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement
instruction sheet included with the Ford Service Function card. Next, either a transfer of data from
the old module to the new module or a manual update must be performed on the VID block. Follow
screen instructions or refer to the supplement instruction sheet included with the Ford Service
Function card. If the VID block has been reprogrammed previously, the scan tool will display a
message. This message will indicate the need to reflash the entire IC.
NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer.
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Powertrain Control Module: Reset Procedure
Purpose for Clearing Codes
Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning
contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset.
After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will
be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and
performance.
A Keep Alive Random Access Memory Reset is done as follows:
During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is
found in the Active Command Modes menu on the New Generation Star scan tool.
If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's
instruction manual.
If an error message is received or the scan tool does not support this function, disconnecting the
battery ground cable for a minimum of 5 minutes may be used as an alternative procedure.
Powertrain Control Module (PCM/KAM Reset)
All OBDII scan tools support the Powertrain Control Module (PCM) reset.
The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic
information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II
system monitors or components have been tested to satisfy a drive cycle, without any other faults
occurring.
The following events occur when a PCM reset is performed:
- Clears the number of Diagnostic Trouble Codes (DTCs).
- Clears the DTCs.
- Clears the freeze frame data.
- Clears diagnostic monitoring test results.
- Resets status of the OBD II system monitors.
- Sets DTC P1000.
NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the
CLEAR button. This function is performed only after retrieval of continuous DTCs.
New Generation Star and Generic Scan Tool
Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM
reset.
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Powertrain Control Module: Removal and Replacement
Compressed Natural Gas Vehicle (NGV) Module
REMOVAL
WARNING
- DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
- IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
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4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
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1. To install, reverse the removal procedure.
- Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Gasoline
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the screw and position the powertrain control module electrical connector out of the
way.
3. Remove the nuts.
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4. Remove the powertrain control module cover.
5. Remove the three pin-type retainers and the under dash sight cover.
6. Remove the Powertrain Control Module (PCM).
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
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Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG)
> Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Driver Module (CNG)
> Component Information > Diagrams > Page 3264
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
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> Component Information > Diagrams > Page 3265
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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> Component Information > Diagrams > Page 3266
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
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> Component Information > Diagrams > Page 3267
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Specifications
Fuel Tank Pressure Sensor: Specifications
Fuel Tank Pressure Sensor 55 Nm
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Component Information > Specifications > Page 3271
Fuel Tank Pressure Sensor: Service and Repair
NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs.
REMOVAL
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the NGV fuel tank pressure sensor.
1 Disconnect the NGV fuel tank pressure sensor electrical connector.
2 Remove the NGV fuel tank pressure sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy.
^ Replace the NGV fuel tank pressure sensor O-ring seal.
^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil
XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to
help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications
Idle Air Control Valve: Specifications
Idle Air Control Valve Bolts 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3275
Idle Air Control Valve: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Idle Air Control (IAC) valve.
4. Remove the idle air control valve hose.
5. Remove the two screws and the idle air control valve.
INSTALLATION
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Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3276
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions
Multiplex Communication Network: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Multiplex Communication Network: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Multiplex Communication Network: Electrical Diagrams
Diagram 14-1
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Diagram 14-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Description and Operation > Module Communication Network
Multiplex Communication Network: Description and Operation Module Communication Network
Principles of Operation
The vehicle has two module communication networks. The Standard Corporate Protocol (SCP)
communication network, which is an unshielded twisted pair cable (data bus plus, Circuit 914
[TN/OG] and data bus minus, Circuit 915 [PK/LB]) and the International Standards Organization
(ISO) 9141 communications network which is a single-wire network(Circuit 70 [LB/W]). Both
networks can be connected to New Generation STAR (NGS) Tester by one connector called the
Data Link Connector (DLC). This makes diagnosis and testing these systems easier by allowing
one smart tester to be able to diagnose and control any module on the two networks from one
connector. The DLC can be found under the instrument panel between the steering column and the
radio.
The ISO 9141 communication network does not permit intermodule communication. When NGS
Tester communicates to modules on the ISO 9141 communication network, NGS Tester must ask
for all information; the modules cannot initiate communications.
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The SCP communication network will remain operational even with the severing of one of the bus
wires. Communications will also continue if one of the bus wires is shorted to ground or battery
positive voltage (B+), or if some but not all termination resistors are lost.
Unlike the SCP communication network, the ISO 9141 communication network will not function if
the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the ISO
9141 communication network loses power or shorts internally, communications to that module will
fail.
The Electronic Crash Sensor (ECS) is connected to the ISO 9141 communication network. The
ECS controls the deployment of the air bags based on sensor input.
The Driver Door Module (DDM) is connected to the SCP communication network. The module
controls many functions including power windows, power locks and keyless remote entry.
The Lighting Control Module (LCM) is connected to the SCP communication network. The LCM
controls both interior and exterior lighting, anti-theft functions and warning chimes.
The Electronic Automatic Temperature Control (EATC) module is connected to the SCP
communication network. The EATC module controls automatic climate functions that maintain the
vehicle at a constant temperature setting.
The Powertrain Control Module (PCM) is connected to the SCP communication network. The PCM
controls the engine performance, electronic ignition, emission controls and on-board diagnostics.
The Natural Gas Vehicle Module (NGVM) calculates fuel level based on inputs from the fuel tank
pressure sensor and the fuel tank temperature sensor. The NGVM then provides a voltage signal
to the instrument cluster to drive the fuel gauge. The NGVM also has separate injector drivers to
run the injectors at the higher operating pressure of natural gas. The NGVM does not perform any
calculations for this function; calibration for the injectors is maintained in the Powertrain Control
Module (PCM).
The anti-lock brake control module is connected to the SCP communication network. The module
controls the brake pressure to the four wheels to keep the vehicle under control while braking.
The Passive Anti-Theft System (PATS) module is on the SCP communication network. The PATS
module communicates with the PCM to disable and start the vehicle based on a signal received
from an encoded ignition key signal.
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Multiplex Communication Network: Description and Operation Module Configuration
NOTE
^ Newly released modules will require configuration after being installed on the vehicle. All
configurable modules will be packaged in a kit which contains a warning label and a multi-language
sheet reemphasizing the requirements to configure replacement modules.
^ The Powertrain Control Module (PCM) has to be flash programmed using a flash cable.
Customer Driven Preferences There are customer preference items that can or need to be
configured on this vehicle. These are items that the customer may or may not want to have
enabled. Typically, customer preference items can be toggled on or off by the use of a Ford
compatible scan tool. You may need to ask the customer which preferences they had enabled prior
to installation of the new module.
To carry out the customer configuration process, use a Ford Service Function (FSF) card and the
NGS Tester. Refer to the Customer Preference Index for modules on the vehicle that have
customer preference items. See: Testing and Inspection/Pinout Values and Diagnostic
Parameters/Module Configuration/Customer Preference Index Configure the items as needed with
a Ford compatible scan tool.
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<--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis
Multiplex Communication Network: Flow of Diagnosis
Module Communication Network
1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious
signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Battery Junction Box (BJB) Fuse 12 (30 A)
^ Wiring harness
^ Loose or corroded connections
^ Anti-lock brake control module
^ Electronic Automatic Temperature Control (EATC) module
^ Passive Anti-Theft System (PATS) module
^ Natural Gas Vehicle Module (NGVM)
^ Electronic Crash Sensor (ECS)
^ Driver Door Module (DDM)
^ Lighting Control Module (LCM)
^ Powertrain Control Module (PCM)
3. If the concern remains after the inspection, connect NGS Tester to the DLC located beneath the
instrument panel and select the vehicle to be tested
from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^
Check that the program card is correctly installed.
^ Check that the correct version of the program card is installed.
^ Check the connections to the vehicle.
^ Check the ignition switch position.
If NGS Tester still does not communicate with the vehicle, GO to Pinpoint Test N.
4. GO to Pinpoint Test PC. See: Pinout Values and Diagnostic Parameters/Module Communication
Network/System Precheck
Module Configuration
1. Visually inspect for obvious signs of electrical damage. Refer to the following chart:
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) Fuse 12 (30 A).
^ Damaged wiring harness
^ Loose or corroded connectors
^ DDM
^ PATS module
2. If the concern remains after inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath the
instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does
not communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch is in RUN position.
If the NGS Tester still will not communicate with the vehicle, refer to Information Bus.
3. Refer to the Symptom Chart. See: Pinout Values and Diagnostic Parameters/Module
Configuration/Symptom Chart
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Multiplex Communication Network: Pinout Values and Diagnostic Parameters
Inspection and Verification (Start Here)
1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious
signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Battery Junction Box (BJB) Fuse 12 (30 A)
^ Wiring harness
^ Loose or corroded connections
^ Anti-lock brake control module
^ Electronic Automatic Temperature Control (EATC) module
^ Passive Anti-Theft System (PATS) module
^ Natural Gas Vehicle Module (NGVM)
^ Electronic Crash Sensor (ECS)
^ Driver Door Module (DDM)
^ Lighting Control Module (LCM)
^ Powertrain Control Module (PCM)
3. If the concern remains after the inspection, connect NGS Tester to the DLC located beneath the
instrument panel and select the vehicle to be tested
from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^
Check that the program card is correctly installed.
^ Check that the correct version of the program card is installed.
^ Check the connections to the vehicle.
^ Check the ignition switch position.
If NGS Tester still does not communicate with the vehicle, GO to Pinpoint Test N.
4. GO to Pinpoint Test PC. See: Module Communication Network/System Precheck
Principles of Operation
The vehicle has two module communication networks. The Standard Corporate Protocol (SCP)
communication network, which is an unshielded twisted pair cable (data bus plus, Circuit 914
[TN/OG] and data bus minus, Circuit 915 [PK/LB]) and the International Standards Organization
(ISO) 9141 communications network which is a single-wire network(Circuit 70 [LB/W]). Both
networks can be connected to New Generation STAR (NGS) Tester by one connector called the
Data Link Connector (DLC). This makes diagnosis and testing these systems easier by allowing
one smart tester to be able to diagnose and control any module on the two networks from one
connector. The DLC can be found under the instrument panel between the steering column and the
radio.
The ISO 9141 communication network does not permit intermodule communication. When NGS
Tester communicates to modules on the ISO 9141 communication network, NGS Tester must ask
for all information; the modules cannot initiate communications.
The SCP communication network will remain operational even with the severing of one of the bus
wires. Communications will also continue if one of the bus wires is shorted to ground or battery
positive voltage (B+), or if some but not all termination resistors are lost.
Unlike the SCP communication network, the ISO 9141 communication network will not function if
the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the ISO
9141 communication network loses power or shorts internally, communications to that module will
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fail.
The Electronic Crash Sensor (ECS) is connected to the ISO 9141 communication network. The
ECS controls the deployment of the air bags based on sensor input.
The Driver Door Module (DDM) is connected to the SCP communication network. The module
controls many functions including power windows, power locks and keyless remote entry.
The Lighting Control Module (LCM) is connected to the SCP communication network. The LCM
controls both interior and exterior lighting, anti-theft functions and warning chimes.
The Electronic Automatic Temperature Control (EATC) module is connected to the SCP
communication network. The EATC module controls automatic climate functions that maintain the
vehicle at a constant temperature setting.
The Powertrain Control Module (PCM) is connected to the SCP communication network. The PCM
controls the engine performance, electronic ignition, emission controls and on-board diagnostics.
The Natural Gas Vehicle Module (NGVM) calculates fuel level based on inputs from the fuel tank
pressure sensor and the fuel tank temperature sensor. The NGVM then provides a voltage signal
to the instrument cluster to drive the fuel gauge. The NGVM also has separate injector drivers to
run the injectors at the higher operating pressure of natural gas. The NGVM does not perform any
calculations for this function; calibration for the injectors is maintained in the Powertrain Control
Module (PCM).
The anti-lock brake control module is connected to the SCP communication network. The module
controls the brake pressure to the four wheels to keep the vehicle under control while braking.
The Passive Anti-Theft System (PATS) module is on the SCP communication network. The PATS
module communicates with the PCM to disable and start the vehicle based on a signal received
from an encoded ignition key signal.
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PC1
Icons Used With Pinpoint Tests
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Test Notes
CAUTION
^ Be careful when probing the fuse junction panel, power distribution box or any connectors.
Damage will result to the connector receptacle if the probe or terminal being used is too large.
^ Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
NOTE: If DTCs are recorded and the symptom is not present when performing the Pinpoint Tests,
an intermittent concern may be the cause. Always check for loose connections and corroded
terminals.
A: Antilock Brake Control Module Doesn't Respond to NGS Tester
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A1
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A2 - A3
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A4 - A5
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B1 - B2
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C1 - C3
D: Natural Gas Veh. Module (NGVM) Doesn't Respond To NGS Tester
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D1 - D2
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D3 - D4
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D5
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E1 - E2
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F1 - F2
G: Powertrain Control Module (PCM) No Response To NGS Tester
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H3
I: No Module/Network Communication - ISO 9141 Network
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I6
J: No Module/Network Communication - SCP Network
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Inspection and Verification (Start Here)
1. Visually inspect for obvious signs of electrical damage. Refer to the following chart:
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) Fuse 12 (30 A).
^ Damaged wiring harness
^ Loose or corroded connectors
^ DDM
^ PATS module
2. If the concern remains after inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath the
instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does
not communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch is in RUN position.
If the NGS Tester still will not communicate with the vehicle, refer to Information Bus.
3. Refer to the Symptom Chart. See: Module Configuration/Symptom Chart
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Principles of Operation
NOTE
^ Newly released modules will require configuration after being installed on the vehicle. All
configurable modules will be packaged in a kit which contains a warning label and a multi-language
sheet reemphasizing the requirements to configure replacement modules.
^ The Powertrain Control Module (PCM) has to be flash programmed using a flash cable.
Customer Driven Preferences There are customer preference items that can or need to be
configured on this vehicle. These are items that the customer may or may not want to have
enabled. Typically, customer preference items can be toggled on or off by the use of a Ford
compatible scan tool. You may need to ask the customer which preferences they had enabled prior
to installation of the new module.
To carry out the customer configuration process, use a Ford Service Function (FSF) card and the
NGS Tester. Refer to the Customer Preference Index for modules on the vehicle that have
customer preference items. See: Module Configuration/Customer Preference Index Configure the
items as needed with a Ford compatible scan tool.
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A1
Icons Used With Pinpoint Tests
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
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Multiplex Communication Network: Service and Repair
Heat Gun Or Equivalent
Special Tool(s)
1. Disconnect the battery ground cable.
2. Strip the wires.
3. Solder the wires.
1 Install the heat shrink tube.
2 Twist the wires together.
3 Solder the wires together.
NOTE: Use rosin core mildly activated (RMA) solder, not acid core solder.
4. Bend the wires back in a straight line.
NOTE: Wait for the solder to cool before moving the wires.
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5. Position the (A) heat shrink tube over the (B) wire repair.
^ Overlap the heat shrink tube on both wires.
6. Use Heat Gun to heat the repaired area until adhesive flows out both ends of the heat shrink
tube. 7. Reconnect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
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Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > PCM Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
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Schematic
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Oxygen Sensor: Specifications
Heated Oxygen Sensor - Front (HO2S) 36-46 Nm
Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm
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H02S Location
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Front
Oxygen Sensor: Service and Repair Front
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S).
3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and
support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
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5. Remove the front heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford
specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation.
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Information > Service and Repair > Front > Page 3400
Oxygen Sensor: Service and Repair Rear
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S).
4. Remove the rear heated oxygen sensor.
INSTALLATION
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Information > Service and Repair > Front > Page 3401
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford
specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Specifications > Page 3405
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
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Sensor, EGR > Component Information > Specifications > Page 3406
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
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5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
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Service Bulletins > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3413
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3415
Powertrain Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle
Article No. 99-4-3
03/08/99
REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V
VEHICLES ONLY
FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97
PROBE 1996-99 CONTOUR, ESCORT, TAURUS
LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN
CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR
LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER,
WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99
EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to update the affected vehicles and to include an
Application Chart for the affected vehicles.
ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket
service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain
reasonably priced, timely PCM programming services at dealerships. Ford has released an
out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are
reprogrammable to update calibration levels or to reprogram a common hardware type to a new
calibration in order to fill a service need without ordering a new PCM.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3416
ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to
handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may
allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to
have modules updated to new calibrations through the Parts Department instead of ordering new
parts.
Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the
module. An aftermarket service center may bring a module to a dealership for a calibration update
or may request an updated calibration be installed to a new service part. The EPA regulations
require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash
Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a
calibration on a PCM out of the vehicle.
The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector.
The proper calibration must be downloaded to the Data Transfer Card through Service Bay
Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is
connected, follow the calibration download instructions displayed on the NGS screen.
The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling
1-800-ROTUNDA.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-26-3
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 203000, 206000, 290000, 690000, 698298
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 3417
Powertrain Control Module: Specifications
Powertrain Control Module Electrical Connector Bolt 4-7 Nm
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Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3420
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3421
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3422
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3423
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3424
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3425
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Diagram Information and Instructions > Page 3426
Powertrain Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Diagram Information and Instructions > Page 3428
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Diagram Information and Instructions > Page 3429
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3430
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3431
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3432
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 3433
Powertrain Control Module: Connector Views
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Diagram Information and Instructions > Page 3434
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Page 3435
Powertrain Control Module: Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
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Repair > Procedures
Powertrain Control Module: Procedures
Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit
(IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration
information specific to the vehicle.
The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire
contents. This is usually due to either an after production strategy change or the Vehicle
Identification (VID) area has been previously reprogrammed and has reached its limit. The VID
block area can be tailored to accommodate various hardware changes made to the vehicle since
production. The VID block is a section of memory within the IC which includes items such as
octane adjust, fuel octane, fuel type, tire size and axle ratio.
Programming a Replacement PCM
A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from
the original PCM before removing from the vehicle. Refer to the flash VID block update procedure.
After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM
config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary
to manually reprogram the VID block. The scan tool is used to perform this procedure and is done
through the "PCM Programming" selection as described by the flash EEPROM procedure below.
Follow screen instructions.
Flash EEPROM Procedure
When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The
Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto
the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash
cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM
Programming" or refer to the flash instruction manual provided in the kit. VID block information can
also be viewed and changed during this procedure.
Flash VID Block Procedure
When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS
flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select
"Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module
Installation". The screen will now display two selections. The first is for old PCM information to be
retrieved and stored within the NGS. The second is for restoring the new PCM with information
which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement
instruction sheet included with the Ford Service Function card. Next, either a transfer of data from
the old module to the new module or a manual update must be performed on the VID block. Follow
screen instructions or refer to the supplement instruction sheet included with the Ford Service
Function card. If the VID block has been reprogrammed previously, the scan tool will display a
message. This message will indicate the need to reflash the entire IC.
NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Procedures > Page 3438
Powertrain Control Module: Reset Procedure
Purpose for Clearing Codes
Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning
contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset.
After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will
be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and
performance.
A Keep Alive Random Access Memory Reset is done as follows:
During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is
found in the Active Command Modes menu on the New Generation Star scan tool.
If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's
instruction manual.
If an error message is received or the scan tool does not support this function, disconnecting the
battery ground cable for a minimum of 5 minutes may be used as an alternative procedure.
Powertrain Control Module (PCM/KAM Reset)
All OBDII scan tools support the Powertrain Control Module (PCM) reset.
The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic
information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II
system monitors or components have been tested to satisfy a drive cycle, without any other faults
occurring.
The following events occur when a PCM reset is performed:
- Clears the number of Diagnostic Trouble Codes (DTCs).
- Clears the DTCs.
- Clears the freeze frame data.
- Clears diagnostic monitoring test results.
- Resets status of the OBD II system monitors.
- Sets DTC P1000.
NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the
CLEAR button. This function is performed only after retrieval of continuous DTCs.
New Generation Star and Generic Scan Tool
Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM
reset.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Procedures > Page 3439
Powertrain Control Module: Removal and Replacement
Compressed Natural Gas Vehicle (NGV) Module
REMOVAL
WARNING
- DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
- IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Procedures > Page 3440
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Procedures > Page 3441
1. To install, reverse the removal procedure.
- Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Gasoline
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the screw and position the powertrain control module electrical connector out of the
way.
3. Remove the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Procedures > Page 3442
4. Remove the powertrain control module cover.
5. Remove the three pin-type retainers and the under dash sight cover.
6. Remove the Powertrain Control Module (PCM).
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3446
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3447
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3448
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 3449
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM
Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM
Power Relay > Page 3455
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 3465
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 3466
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 3472
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 3473
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3474
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3475
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3476
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Technical Service Bulletins > Page 3477
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3481
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 16-24 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3488
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3489
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3490
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Cylinder Head Temperature (CHT) Sensor 25-30 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3494
Engine Temperature Sensor: Service and Repair
REMOVAL
1. Remove the lower intake manifold.
2. Disconnect the electrical connector from the Cylinder Head Temperature (CHT) sensor.
3. If necessary, remove the wiring connector.
4. Remove the cylinder head temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications
Fuel Tank Pressure Sensor: Specifications
Fuel Tank Pressure Sensor 55 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications > Page 3498
Fuel Tank Pressure Sensor: Service and Repair
NOTE: Perform the Fuel Pressure Release Procedure prior to making any repairs.
REMOVAL
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the NGV fuel tank pressure sensor.
1 Disconnect the NGV fuel tank pressure sensor electrical connector.
2 Remove the NGV fuel tank pressure sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy.
^ Replace the NGV fuel tank pressure sensor O-ring seal.
^ Lubricate the NGV fuel tank pressure sensor O-ring seal with Super Premium 5W30 engine oil
XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to installation, to
help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3502
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3507
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3508
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3509
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3510
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3511
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3512
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3513
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3514
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3515
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3516
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Emissions/Engine Controls - Driveability Diagnosis > Page 3517
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3518
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3519
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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Emissions/Engine Controls - Driveability Diagnosis > Page 3520
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3521
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Oxygen Sensor: Specifications
Heated Oxygen Sensor - Front (HO2S) 36-46 Nm
Heated Oxygen Sensor - Rear (HO2S) 36-46 Nm
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H02S Location
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Instructions > Page 3526
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Instructions > Page 3527
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Instructions > Page 3528
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Instructions > Page 3529
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Instructions > Page 3531
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Instructions > Page 3532
Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Instructions > Page 3533
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Instructions > Page 3538
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front
Oxygen Sensor: Service and Repair Front
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the right side Heated Oxygen Sensor (HO2S).
3. Disconnect the electrical connector from the left side heated oxygen sensor. 4. Raise and
support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
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5. Remove the front heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L49-AA or equivalent meeting Ford
specification ESE-M12A4-A to the threads of the heated oxygen sensors prior to installation.
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Oxygen Sensor: Service and Repair Rear
EGO Sensor Wrench
Special Tool(s)
REMOVAL
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
3. Disconnect the electrical connector from the rear Heated Oxygen Sensor (HO2S).
4. Remove the rear heated oxygen sensor.
INSTALLATION
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1. To install, reverse the removal procedure.
NOTE: Apply a light coat of Anti-Seize Compound F6AZ-9L494AA or equivalent meeting Ford
specification ESE-M12A4A to the threads of the heated oxygen sensors prior to installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
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Page 3547
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
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Page 3548
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
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Page 3549
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications >
Page 3556
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications >
Page 3557
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications >
Page 3558
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications >
Page 3559
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3565
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3566
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3567
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3568
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3569
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3570
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3571
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3572
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3573
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3574
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3575
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3576
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3577
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 3584
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 3585
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 3586
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 3587
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor (VSS) Bolt 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3593
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3594
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3595
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3596
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3597
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3598
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3599
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3600
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3601
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3602
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3603
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3604
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3605
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's
Set/Low Power
Catalytic Converter: Customer Interest CNG Fuel System - Hard Start/DTC's Set/Low Power
Article No. 03-20-6
10/13/03
^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND
5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L
ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150
ISSUE
Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector
performance, resulting from fuel quality. The conditions (in approximate order of their occurrence)
include:
^ Loss Of Power At Heavy Load
^ DTC Codes For Lean Fuel
^ Rough Idle
^ Hard Start
^ Plugged Catalytic Converter
^ No Start
NOTE
THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE
DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER.
ACTION The root cause of these conditions may be due to either excessive or insufficient
carryover compressor oil from the CNG fill station.
Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of
10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous
fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the
injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the
injector is opened, but may delay opening or prevent an injector from opening at all. The deposit
may increase over time and may further delay the injector opening time. Insufficient oil (less than
10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to
open the injector, especially when cold. In either case, the customer may first notice a loss of
power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel
logic adjustment range for injector pulse width is exceeded.
Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector
partially or completely shut and cause a hard start or no start. A hard start and temporary rough
idle when cold is caused by some of the injectors being marginally functional at the start, and the
other injectors becoming functional as they warm up from. engine heat and soften the oil deposit
enough to release the stuck pintle.
A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely
to form injector deposits than either type alone. Vehicles that fill from many stations are more likely
to exhibit the conditions. The oil type may also change if a station compressor is serviced or
replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly
evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has
collected in a tank can still remain available to mix even after the compressor oil has been
changed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's
Set/Low Power > Page 3615
SERVICE PROCEDURE
Different actions are required according to the cause and severity of the conditions exhibited. The
actions to correct an insufficient oil situation are different than the actions to correct an excessive
oil situation.
Customers reporting the conditions listed above may determine their situation by some quick
checks on the vehicle.
EVIDENCE OF INSUFFICIENT OIL INCLUDES:
^ No oil film on fill station nozzle outlet or vehicle fill receptacle.
^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl.
^ A dry coalescing filter element.
EVIDENCE OF EXCESSIVE OIL INCLUDES:
^ Heavy oil film on station nozzle outlet and vehicle fill receptacle.
^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the
element.
^ Fully oil-soaked coalescing element.
^ Liquid oil found in fuel tanks or lines opened for other service.
Fill stations that derive compressed natural gas from liquefied natural gas should have an oil
injection system. The extremely cold temperature of liquefied natural gas literally "freezes out"
lubricants and these lubricants need to be replaced after the gas returns to its vapor phase.
Customers operating their own fill stations (usually fleet customers) should routinely check that all
installed equipment is operating properly and is serviced at the intervals recommended by the
component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate
filters, and coalescing filters. A fill station may have many filters at different points in the flow
stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet,
and the dispenser. A particulate filter that becomes clogged will indicate its condition by high
differential pressures or reduced total flow. A coalescing filter that is not drained often enough can
fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream
components with no obvious indication at the filter. A fill station technician draining a pressurized
coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble,
again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than
normal due to poor sealing at the piston rings. A fill station maintenance routine should include
recording the oil volume drained from downstream filters. This record can be used to compare the
oil volume added to the compressor. This will reveal compressor wear and the associated
maintenance requirements due to this wear.
Customers who maintain their own vehicles should consider measuring and recording the oil level
found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in
several vehicles in a short period of time may indicate that a fueling station used by those vehicles
requires service to reduce its compressor oil carryover.
Fleet customers should inquire about the maintenance practices of the fill stations they use.
For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty
Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter
bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil
in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in
the fuel does not affect the filter element life, so the element should be replaced at the normal
30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil.
It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush
Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel
injectors to return to their normal function. In some fuel environments it may be necessary to
perform this cleaning on a regular basis.
NOTE
IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE
APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3
FOR THE INJECTOR CLEANING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard Start/DTC's
Set/Low Power > Page 3616
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 >
CNG Fuel System - Hard Start/DTC's Set/Low Power
Catalytic Converter: All Technical Service Bulletins CNG Fuel System - Hard Start/DTC's Set/Low
Power
Article No. 03-20-6
10/13/03
^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND
5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L
ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150
ISSUE
Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector
performance, resulting from fuel quality. The conditions (in approximate order of their occurrence)
include:
^ Loss Of Power At Heavy Load
^ DTC Codes For Lean Fuel
^ Rough Idle
^ Hard Start
^ Plugged Catalytic Converter
^ No Start
NOTE
THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE
DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER.
ACTION The root cause of these conditions may be due to either excessive or insufficient
carryover compressor oil from the CNG fill station.
Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of
10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous
fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the
injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the
injector is opened, but may delay opening or prevent an injector from opening at all. The deposit
may increase over time and may further delay the injector opening time. Insufficient oil (less than
10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to
open the injector, especially when cold. In either case, the customer may first notice a loss of
power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel
logic adjustment range for injector pulse width is exceeded.
Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector
partially or completely shut and cause a hard start or no start. A hard start and temporary rough
idle when cold is caused by some of the injectors being marginally functional at the start, and the
other injectors becoming functional as they warm up from. engine heat and soften the oil deposit
enough to release the stuck pintle.
A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely
to form injector deposits than either type alone. Vehicles that fill from many stations are more likely
to exhibit the conditions. The oil type may also change if a station compressor is serviced or
replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly
evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has
collected in a tank can still remain available to mix even after the compressor oil has been
changed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 >
CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3622
SERVICE PROCEDURE
Different actions are required according to the cause and severity of the conditions exhibited. The
actions to correct an insufficient oil situation are different than the actions to correct an excessive
oil situation.
Customers reporting the conditions listed above may determine their situation by some quick
checks on the vehicle.
EVIDENCE OF INSUFFICIENT OIL INCLUDES:
^ No oil film on fill station nozzle outlet or vehicle fill receptacle.
^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl.
^ A dry coalescing filter element.
EVIDENCE OF EXCESSIVE OIL INCLUDES:
^ Heavy oil film on station nozzle outlet and vehicle fill receptacle.
^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the
element.
^ Fully oil-soaked coalescing element.
^ Liquid oil found in fuel tanks or lines opened for other service.
Fill stations that derive compressed natural gas from liquefied natural gas should have an oil
injection system. The extremely cold temperature of liquefied natural gas literally "freezes out"
lubricants and these lubricants need to be replaced after the gas returns to its vapor phase.
Customers operating their own fill stations (usually fleet customers) should routinely check that all
installed equipment is operating properly and is serviced at the intervals recommended by the
component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate
filters, and coalescing filters. A fill station may have many filters at different points in the flow
stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet,
and the dispenser. A particulate filter that becomes clogged will indicate its condition by high
differential pressures or reduced total flow. A coalescing filter that is not drained often enough can
fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream
components with no obvious indication at the filter. A fill station technician draining a pressurized
coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble,
again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than
normal due to poor sealing at the piston rings. A fill station maintenance routine should include
recording the oil volume drained from downstream filters. This record can be used to compare the
oil volume added to the compressor. This will reveal compressor wear and the associated
maintenance requirements due to this wear.
Customers who maintain their own vehicles should consider measuring and recording the oil level
found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in
several vehicles in a short period of time may indicate that a fueling station used by those vehicles
requires service to reduce its compressor oil carryover.
Fleet customers should inquire about the maintenance practices of the fill stations they use.
For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty
Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter
bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil
in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in
the fuel does not affect the filter element life, so the element should be replaced at the normal
30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil.
It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush
Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel
injectors to return to their normal function. In some fuel environments it may be necessary to
perform this cleaning on a regular basis.
NOTE
IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE
APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3
FOR THE INJECTOR CLEANING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 03-20-6 > Oct > 03 >
CNG Fuel System - Hard Start/DTC's Set/Low Power > Page 3623
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3628
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3629
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3630
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3631
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Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3632
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Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3633
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Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3634
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Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3635
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3636
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-9-7 > May > 01 >
Emissions/Engine Controls - Driveability Diagnosis > Page 3657
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Emissions/Engine Controls - Driveability Diagnosis > Page 3658
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3659
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3660
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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Emissions/Engine Controls - Driveability Diagnosis > Page 3661
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Emissions/Engine Controls - Driveability Diagnosis > Page 3662
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Information > Technical Service Bulletins > Page 3663
Catalytic Converter: Locations
Exhaust System
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Exhaust System
Dual Exhaust Catalyst Configuration
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Exhaust System
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Exhaust System
Single Exhaust Catalyst Configuration
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Catalytic Converter: Service and Repair
Removal
1. Raise and support the vehicle.
2. Disconnect the oxygen sensor connectors.
3. Remove the two nuts.
4. Remove the Three Way Catalytic Converter (TWC).
^ Remove the nuts, bolts, damper and gasket.
^ Remove the TWC.
Installation
1. Position the three way catalytic converters and install the two nuts.
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2. Install a new gasket, bolts, nuts and damper. 3. Connect the heated oxygen sensor connectors.
4. Lower the vehicle.
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Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
Technical Service Bulletin # 02B02 Date: 030301
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Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3679
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
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Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3680
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Attachment I - Administrative Information
OASIS
You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles
built in the affected time period are eligible for this program because many are no longer in law
enforcement duty. Ford has used motor vehicle and U.S. postal records to purge vehicles known to
no longer be currently in law enforcement duty. If you encounter a vehicle currently in law
enforcement duty that is not listed in OASIS see below. Also see "FINAL ELIGIBILITY CHECK"
below for additional restrictions.
VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY
Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law
enforcement duty & subjected to risk of high-speed high-energy rear impact collisions may have
02B02 performed at no-charge at the request of a law enforcement official. Documentation of law
enforcement use such as a letter on department letterhead with VIN is required. Please call to
request the addition to OASIS of a non-P71 Crown Victoria vehicle currently in law enforcement
duty.
FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS
In addition to preliminary eligibility verification through OASIS please verify by visual inspection the
vehicle is currently in law enforcement duty.
Under 02B02 all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge.
Many CVPI vehicles are sold to the secondary market (taxi private use) after retirement from law
enforcement duty. Based on vehicle registration data available to Ford some of these secondary
market vehicles may inadvertently receive an owner letter. Therefore possession of a letter from
Ford does not in itself indicate eligibility for 02B02. CVPI vehicles in the secondary market are not
eligible for no-charge upgrades under the terms of program 02B02. If the CVPI is no longer
currently used in law enforcement duty and the VIN is active in OASIS submit a claim for VIN
closure (see ATTACHMENT II).
PLEASE NOTE
If requested by your law enforcement fleet customer correct in-stock vehicles before delivery.
You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if
you have an involved vehicle in stock. When calling this number identify Optional Upgrade Program
02B02 and have the VIN of the dealer stock vehicle to be serviced.
DEALER-OWNER CONTACT
An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in
the affected time period are eligible for this program. Ford has used motor vehicle and U.S. postal
records to purge vehicles known to no longer be currently in law enforcement duty.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14
Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14. Warranty claims
submitted for performing TSB 01-21-14 on or after September 27, 2002 will not be processed.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3683
OWNER REFUNDS FOR TSB 01-21-14
Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September
27, 2002 on CVPI vehicles currently in law enforcement duty. No other requests for refunds
including repairs not endorsed by Ford Motor Company will be accepted. Refer to ACESII manual
for refund information.
Program Code: 02B02
Misc. Expense: REFUND
Misc. Expense: ADMIN
Misc. Expense: 0.2 Hr.
RENTAL CARS
The use of rental vehicles is not authorized for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS ORDERING INFORMATION
LAW ENFORCEMENT VEHICLES:
Beginning October 22, 2002 law enforcement fleets using CVPI vehicles currently in law
enforcement duty will be asked to register using their Fleet Identification Number (FIN) to allow
priority parts ordering. Fleets without web access or FIN codes may register at the Police
Interceptor Registration Center via telephone. Eligible fleets may establish a FIN code by calling
the Fleet Customer Information Center.
Once on the website the fleet representative will input fleet name contact and vehicle information.
The fleet representative must also certify he/she agrees to review information on the website.
Fleets without web access will be sent information contained on the website. Once the required
information is provided an Authorization Number will be generated by the website. The fleet will
provide their dealer(s) of choice the Authorization Number which will allow priority ordering of parts.
Dealers will then contact the Low Volume Coordination Center and provide the fleets Authorization
Number to order parts (up to the authorized quantity). A verification of the Authorization Number
will be performed and the parts will be ordered for you by the Program Coordination Center.
Fleets who do not register may still order parts through their servicing dealer(s); however priority
fulfillment of parts orders will be given to registered fleets.
Depending upon law enforcement fleet registrations upgrade kits should arrive at your dealership
after October 28, 2002. It is estimated that 10% of total kits required to upgrade CVPI vehicles will
be available by October 31, 2002. No kits will be available for law enforcement fleets that choose
not to register or for retail purchase and installation until supply exceeds registered law
enforcement demand. It is anticipated that parts ordering restrictions will be removed beginning
January 2, 2003.
Attachment III - Technical Information
OVERVIEW
This procedure provides details for installation of the following:
For all affected vehicles
^ Two (2) rear axle shields
^ One (1) differential cover shield
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^ Two (2) fuel tank strap shields
Additional parts required for 1998 through 2003 model year vehicles
^ Two (2) foam pads onto the evaporative emissions canister
^ Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front
edge of the canister) with three (3) rivets
SERVICE PROCEDURE
1. Raise the vehicle on a hoist.
2. NOTE: Shields are molded with "LH" and "RH" to ease identification.
Install the left and right axle shields being sure to position them so there is clearance between the
shield and the stabilizer bar as illustrated. On 1992 to 1997 model year vehicles, be sure the ABS
circuit wiring harness is not pinched under the shield and the right side parking brake cable is
positioned in the notch molded into the shield. Tighten the clamps to 6 Nm (53 lb-in). See Figures 1
and 2.
In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere
with clamp installation. If necessary, grind away only enough excess weld material to allow for
correct seating of the shield and clamp onto the axle. DO NOT grind the parent metal.
3. CAUTION: Tie straps, which are required for 1998 to 2002 model year vehicles only, have
specific heat resistant properties. Use of a tie strap other than what is supplied in the kit can
jeopardize the repair. Also, correct orientation of the tie strap is critical to the repair. The head of
the tie strap must be positioned on the forward-facing side of the shock mount bracket.
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On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the
shock absorber lower mount bracket as illustrated. If necessary, use pliers and LIGHT force to
engage the locking feature of the tie strap. DO NOT STRETCH THE TIE STRAP
UNNECESSARILY. See Figure 3.
4. On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring
leading to each rear wheel. Position the convolute so it is up against the grommet as shown in the
illustration. Secure with vinyl tape. See Figure 4.
5. CAUTION: Do not loosen or remove more than three (3) differential cover bolts at any one time
or a leak may develop.
NOTE: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag
(2002 to 2003 model year vehicles only) interferes with the installation of the differential cover
shield, relocate the tag(s) as necessary to another bolt location on the cover. In some instances,
the tag may simply need to be rotated to avoid interference with the shield installation.
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Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time.
See Figure 5.
6. Remove and discard the three (3) differential cover bolts located at the 4, 6 and 8 o'clock
positions. Position the differential cover shield and press into place. The cover should fit snug over
the existing bolts. Install the three (3) new bolts. Tighten all loosened or removed bolts to 45 Nm
(33 lb-ft). See Figure 5. Be sure to also tighten the axle tag bolt(s) to specification.
17. CAUTION: The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure
to install them in the correct location and so that they are oriented from the outside toward the
center of the vehicle.
NOTE:
Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield
installation. Use a rubber mallet to lightly tap the shields into position only if necessary. Install the
left and right fuel tank strap shields as follows. See Figure 6.
a) Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the
center of the vehicle.
b) Position the long tab up into the strap bracket.
c) Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield.
d) Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive
strip and, while holding the upper portion against the fuel tank flange, secure the two halves firmly
together.
NOTE
^ For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle.
^ For 1998 to 2003 model year vehicles, continue with this procedure.
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8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the
Z-bracket.
9. Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes.
Then, measuring from the edge of either of the two bolt holes, mark the centerline at 50 mm (2-in),
101 mm (4-in) and at 152 mm (6-in). See Figure 7.
10. CAUTION: DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or
an abundance of tape 12 mm (1/2-inch) from the tip of the drill bit. Reinstall one of the removed
bolts to hold the canister securely, then drill the three, 5 mm (13/64-inch) rivet holes through the
Z-bracket and the evaporative emissions canister mounting flange. See Figure 8.
11. Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and
lower the canister off of the studs and disconnect the canister purge valve electrical connector.
Discard both removed canister bolts.
12. Remove and discard the two (2) J-nuts from the evaporative emissions canister flange.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3688
13. Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface
of the canister. Affix the two (2) self-adhesive foam pads onto the canister in the position shown in
the illustration. See Figure 9.
14. Reconnect the canister purge valve, then position the evaporative emissions canister and
install the two (2) retaining nuts finger tight.
15. CAUTION: The rivets supplied in the kit provide a high clamp-load and MUST be used. Using
rivets other than what is supplied in the kit may jeopardize the repair.
NOTE:
The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets
are very sturdy and may be difficult to install with a small, hand-held pop rivet installer. The use of a
large capacity or air/hydraulic rivet installer is recommended but is not necessary.
Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in).
16. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3689
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3690
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3691
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3692
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3693
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3694
Attachment I - S1
OASIS
When a customer requests inspection of an Upgrade Kit installation use OASIS to determine
eligibility for this inspection program. Only vehicles having previously had the Upgrade Kit installed
are eligible for this inspection program.
PLEASE NOTE
Inspect before delivery all upgraded vehicles in stock with build dates on or before October 21,
2002.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ A part quantity of three (3) [rivets] should be entered on the ACES II claim.
OWNER REFUNDS
Owner refunds are not applicable for this inspection.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this inspection.
Attachment II - S1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3695
LABOR ALLOWANCES FOR 02B02 INSPECTION
Reference the original 02B02 dealer bulletin for first-time Upgrade kit installation labor times and
technical instructions. Inspections do not apply to vehicles that have not had 02B02 performed
previously.
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels. Effective immediately follow the normal order process for Stock Orders and
Interim Orders. For Emergency Orders for the first 30 days following launch, call 1-800-325-5621.
After 30 days follow the normal order process for Emergency Orders.
NOTE:
A part quantity of three (3) [rivets] should be entered on the ACES II claim.
ORDER INFORMATION
The DOR/COR for this program is 50287. This number identifies parts ordered for this Customer
Satisfaction Program through the Special Service Support Center (1-800-325-5621).
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - S1
CERTAIN 1998 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR
(CVPI) VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY - INSPECTION OF OPTIONAL
POLICE INTERCEPTOR PACKAGE UPGRADE
KIT INSTALLATION
This procedure involves inspecting the evaporative emissions canister mounting modifications to
see if they conform to the 02B02 Attachment III technical instructions. Based upon vehicle
inspections and a vehicle survey, Ford Motor Company has found that some technicians are not
removing the bolts and J-nuts affixing the evaporative emissions canister to the underbody of the
trunk as instructed. Specifically, proper installation of the evaporative canister rivets and removal of
the original bolts and J-nuts cannot be skipped and must be completed properly to provide the full
benefit of the optional upgrade.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3696
Provided here is a check sheet to inspect for proper modification of the evaporative emissions
canister mounting. The check sheet will help ensure that Steps 8 through 15 of the original 02B02
upgrade have been followed. Check off each item as you inspect it, then answer whether the
original installation was done properly or if corrections were required. If any corrections were done,
list them in the space provided. At the end of the entire procedure, sign and date the last page
certifying the validity of the installation. Retain this inspection sheet in the dealer's vehicle service
file.
WARNING!
ALL STEPS OF THE ORIGINAL INSTALLATION PROCEDURE MUST BE PERFORMED AS
WRITTEN WITHOUT ANY MODIFICATION TO PROVIDE THE FULL BENEFIT OF THE
OPTIONAL UPGRADE.
REFER TO THE ATTACHMENT III FOUND ON THE PTS WEBSITE TO VIEW VIDEO CLIPS OF
CERTAIN REPAIR STEPS.
IMPORTANT NOTES
CHECKOFF EACH ITEM AS YOU INSPECT IT, THEN ANSWER WHETHER THE ORIGINAL
INSTALLATION WAS DONE PROPERLY. IF ANY CORRECTIONS WERE REQUIRED, LIST
THEM IN THE SPACE PROVIDED.
ANY DISCREPANCIES TO THE 02B02 INSTALLATION PROCEDURES MUST BE
CORRECTED.
THIS DOCUMENT SHOULD BE SIGNED BY BOTH THE SERVICING TECHNICIAN AND THE
SERVICE MANAGER AND BE MAINTAINED IN THE DEALER'S VEHICLE SERVICE FILE,
STAPLED TO THE HARD COPY OF THE REPAIR ORDER.
HAVE A COPY OF THE ORIGINAL 02B02 ATTACHMENT III AVAILABLE FOR REFERENCE
DURING THIS INSPECTION PROCEDURE.
1992 THROUGH 1997 CVPI MODELS ARE NOT INVOLVED IN THIS FOLLOW-UP INSPECTION
PROCEDURE BECAUSE EVAPORATIVE EMISSIONS CANISTER MOUNTING MODIFICATIONS
ARE NOT PART OF THE UPGRADE KIT FOR THOSE MODEL YEARS.
INSPECTION
1. Evaporative Emissions Canister Inspection
WARNING:
DO NOT LEAVE BOLTS AND J-NUTS IN PLACE. THE RIVETS ARE INTENDED TO REPLACE
CANISTER BOLTS AND J-NUTS. THEY ARE NOT UTILIZED TO STRENGTHEN THE
MECHANICAL CONNECTION BETWEEN THE Z-BRACKET AND THE EVAPORATIVE
EMISSIONS CANISTER MOUNTING FLANGE. USING RIVETS OTHER THAN THE SUPPLIED
HIGH CLAMP-LOAD RIVETS CAN JEOPARDIZE THE REPAIR.
NOTE:
Field audits have revealed portions of this repair are not being performed properly. Listed here are
examples of what was found:
^ Bolts and J-nuts still installed - rivets installed (correctly or incorrectly)
^ Bolts and J-nuts still installed - rivets NOT installed
^ Only J-nuts still installed - rivets installed
^ Wrong number of rivets installed
^ Rivets not properly spaced along Z-bracket
^ Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to
evap canister)
If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will
need to be drilled out to allow removal of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3697
J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02
Attachment III.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3698
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3699
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3700
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3701
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3702
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3703
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3704
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Recalls for Evaporative
Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3705
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
Technical Service Bulletin # 02B02 Date: 030301
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3711
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3712
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3713
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3714
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3715
Attachment I - Administrative Information
OASIS
You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles
built in the affected time period are eligible for this program because many are no longer in law
enforcement duty. Ford has used motor vehicle and U.S. postal records to purge vehicles known to
no longer be currently in law enforcement duty. If you encounter a vehicle currently in law
enforcement duty that is not listed in OASIS see below. Also see "FINAL ELIGIBILITY CHECK"
below for additional restrictions.
VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY
Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law
enforcement duty & subjected to risk of high-speed high-energy rear impact collisions may have
02B02 performed at no-charge at the request of a law enforcement official. Documentation of law
enforcement use such as a letter on department letterhead with VIN is required. Please call to
request the addition to OASIS of a non-P71 Crown Victoria vehicle currently in law enforcement
duty.
FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS
In addition to preliminary eligibility verification through OASIS please verify by visual inspection the
vehicle is currently in law enforcement duty.
Under 02B02 all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge.
Many CVPI vehicles are sold to the secondary market (taxi private use) after retirement from law
enforcement duty. Based on vehicle registration data available to Ford some of these secondary
market vehicles may inadvertently receive an owner letter. Therefore possession of a letter from
Ford does not in itself indicate eligibility for 02B02. CVPI vehicles in the secondary market are not
eligible for no-charge upgrades under the terms of program 02B02. If the CVPI is no longer
currently used in law enforcement duty and the VIN is active in OASIS submit a claim for VIN
closure (see ATTACHMENT II).
PLEASE NOTE
If requested by your law enforcement fleet customer correct in-stock vehicles before delivery.
You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if
you have an involved vehicle in stock. When calling this number identify Optional Upgrade Program
02B02 and have the VIN of the dealer stock vehicle to be serviced.
DEALER-OWNER CONTACT
An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in
the affected time period are eligible for this program. Ford has used motor vehicle and U.S. postal
records to purge vehicles known to no longer be currently in law enforcement duty.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14
Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14. Warranty claims
submitted for performing TSB 01-21-14 on or after September 27, 2002 will not be processed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3716
OWNER REFUNDS FOR TSB 01-21-14
Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September
27, 2002 on CVPI vehicles currently in law enforcement duty. No other requests for refunds
including repairs not endorsed by Ford Motor Company will be accepted. Refer to ACESII manual
for refund information.
Program Code: 02B02
Misc. Expense: REFUND
Misc. Expense: ADMIN
Misc. Expense: 0.2 Hr.
RENTAL CARS
The use of rental vehicles is not authorized for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS ORDERING INFORMATION
LAW ENFORCEMENT VEHICLES:
Beginning October 22, 2002 law enforcement fleets using CVPI vehicles currently in law
enforcement duty will be asked to register using their Fleet Identification Number (FIN) to allow
priority parts ordering. Fleets without web access or FIN codes may register at the Police
Interceptor Registration Center via telephone. Eligible fleets may establish a FIN code by calling
the Fleet Customer Information Center.
Once on the website the fleet representative will input fleet name contact and vehicle information.
The fleet representative must also certify he/she agrees to review information on the website.
Fleets without web access will be sent information contained on the website. Once the required
information is provided an Authorization Number will be generated by the website. The fleet will
provide their dealer(s) of choice the Authorization Number which will allow priority ordering of parts.
Dealers will then contact the Low Volume Coordination Center and provide the fleets Authorization
Number to order parts (up to the authorized quantity). A verification of the Authorization Number
will be performed and the parts will be ordered for you by the Program Coordination Center.
Fleets who do not register may still order parts through their servicing dealer(s); however priority
fulfillment of parts orders will be given to registered fleets.
Depending upon law enforcement fleet registrations upgrade kits should arrive at your dealership
after October 28, 2002. It is estimated that 10% of total kits required to upgrade CVPI vehicles will
be available by October 31, 2002. No kits will be available for law enforcement fleets that choose
not to register or for retail purchase and installation until supply exceeds registered law
enforcement demand. It is anticipated that parts ordering restrictions will be removed beginning
January 2, 2003.
Attachment III - Technical Information
OVERVIEW
This procedure provides details for installation of the following:
For all affected vehicles
^ Two (2) rear axle shields
^ One (1) differential cover shield
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3717
^ Two (2) fuel tank strap shields
Additional parts required for 1998 through 2003 model year vehicles
^ Two (2) foam pads onto the evaporative emissions canister
^ Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front
edge of the canister) with three (3) rivets
SERVICE PROCEDURE
1. Raise the vehicle on a hoist.
2. NOTE: Shields are molded with "LH" and "RH" to ease identification.
Install the left and right axle shields being sure to position them so there is clearance between the
shield and the stabilizer bar as illustrated. On 1992 to 1997 model year vehicles, be sure the ABS
circuit wiring harness is not pinched under the shield and the right side parking brake cable is
positioned in the notch molded into the shield. Tighten the clamps to 6 Nm (53 lb-in). See Figures 1
and 2.
In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere
with clamp installation. If necessary, grind away only enough excess weld material to allow for
correct seating of the shield and clamp onto the axle. DO NOT grind the parent metal.
3. CAUTION: Tie straps, which are required for 1998 to 2002 model year vehicles only, have
specific heat resistant properties. Use of a tie strap other than what is supplied in the kit can
jeopardize the repair. Also, correct orientation of the tie strap is critical to the repair. The head of
the tie strap must be positioned on the forward-facing side of the shock mount bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3718
On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the
shock absorber lower mount bracket as illustrated. If necessary, use pliers and LIGHT force to
engage the locking feature of the tie strap. DO NOT STRETCH THE TIE STRAP
UNNECESSARILY. See Figure 3.
4. On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring
leading to each rear wheel. Position the convolute so it is up against the grommet as shown in the
illustration. Secure with vinyl tape. See Figure 4.
5. CAUTION: Do not loosen or remove more than three (3) differential cover bolts at any one time
or a leak may develop.
NOTE: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag
(2002 to 2003 model year vehicles only) interferes with the installation of the differential cover
shield, relocate the tag(s) as necessary to another bolt location on the cover. In some instances,
the tag may simply need to be rotated to avoid interference with the shield installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3719
Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time.
See Figure 5.
6. Remove and discard the three (3) differential cover bolts located at the 4, 6 and 8 o'clock
positions. Position the differential cover shield and press into place. The cover should fit snug over
the existing bolts. Install the three (3) new bolts. Tighten all loosened or removed bolts to 45 Nm
(33 lb-ft). See Figure 5. Be sure to also tighten the axle tag bolt(s) to specification.
17. CAUTION: The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure
to install them in the correct location and so that they are oriented from the outside toward the
center of the vehicle.
NOTE:
Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield
installation. Use a rubber mallet to lightly tap the shields into position only if necessary. Install the
left and right fuel tank strap shields as follows. See Figure 6.
a) Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the
center of the vehicle.
b) Position the long tab up into the strap bracket.
c) Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield.
d) Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive
strip and, while holding the upper portion against the fuel tank flange, secure the two halves firmly
together.
NOTE
^ For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle.
^ For 1998 to 2003 model year vehicles, continue with this procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3720
8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the
Z-bracket.
9. Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes.
Then, measuring from the edge of either of the two bolt holes, mark the centerline at 50 mm (2-in),
101 mm (4-in) and at 152 mm (6-in). See Figure 7.
10. CAUTION: DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or
an abundance of tape 12 mm (1/2-inch) from the tip of the drill bit. Reinstall one of the removed
bolts to hold the canister securely, then drill the three, 5 mm (13/64-inch) rivet holes through the
Z-bracket and the evaporative emissions canister mounting flange. See Figure 8.
11. Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and
lower the canister off of the studs and disconnect the canister purge valve electrical connector.
Discard both removed canister bolts.
12. Remove and discard the two (2) J-nuts from the evaporative emissions canister flange.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3721
13. Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface
of the canister. Affix the two (2) self-adhesive foam pads onto the canister in the position shown in
the illustration. See Figure 9.
14. Reconnect the canister purge valve, then position the evaporative emissions canister and
install the two (2) retaining nuts finger tight.
15. CAUTION: The rivets supplied in the kit provide a high clamp-load and MUST be used. Using
rivets other than what is supplied in the kit may jeopardize the repair.
NOTE:
The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets
are very sturdy and may be difficult to install with a small, hand-held pop rivet installer. The use of a
large capacity or air/hydraulic rivet installer is recommended but is not necessary.
Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in).
16. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3722
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3723
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3724
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3725
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3726
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3727
Attachment I - S1
OASIS
When a customer requests inspection of an Upgrade Kit installation use OASIS to determine
eligibility for this inspection program. Only vehicles having previously had the Upgrade Kit installed
are eligible for this inspection program.
PLEASE NOTE
Inspect before delivery all upgraded vehicles in stock with build dates on or before October 21,
2002.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ A part quantity of three (3) [rivets] should be entered on the ACES II claim.
OWNER REFUNDS
Owner refunds are not applicable for this inspection.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this inspection.
Attachment II - S1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3728
LABOR ALLOWANCES FOR 02B02 INSPECTION
Reference the original 02B02 dealer bulletin for first-time Upgrade kit installation labor times and
technical instructions. Inspections do not apply to vehicles that have not had 02B02 performed
previously.
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels. Effective immediately follow the normal order process for Stock Orders and
Interim Orders. For Emergency Orders for the first 30 days following launch, call 1-800-325-5621.
After 30 days follow the normal order process for Emergency Orders.
NOTE:
A part quantity of three (3) [rivets] should be entered on the ACES II claim.
ORDER INFORMATION
The DOR/COR for this program is 50287. This number identifies parts ordered for this Customer
Satisfaction Program through the Special Service Support Center (1-800-325-5621).
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - S1
CERTAIN 1998 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR
(CVPI) VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY - INSPECTION OF OPTIONAL
POLICE INTERCEPTOR PACKAGE UPGRADE
KIT INSTALLATION
This procedure involves inspecting the evaporative emissions canister mounting modifications to
see if they conform to the 02B02 Attachment III technical instructions. Based upon vehicle
inspections and a vehicle survey, Ford Motor Company has found that some technicians are not
removing the bolts and J-nuts affixing the evaporative emissions canister to the underbody of the
trunk as instructed. Specifically, proper installation of the evaporative canister rivets and removal of
the original bolts and J-nuts cannot be skipped and must be completed properly to provide the full
benefit of the optional upgrade.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3729
Provided here is a check sheet to inspect for proper modification of the evaporative emissions
canister mounting. The check sheet will help ensure that Steps 8 through 15 of the original 02B02
upgrade have been followed. Check off each item as you inspect it, then answer whether the
original installation was done properly or if corrections were required. If any corrections were done,
list them in the space provided. At the end of the entire procedure, sign and date the last page
certifying the validity of the installation. Retain this inspection sheet in the dealer's vehicle service
file.
WARNING!
ALL STEPS OF THE ORIGINAL INSTALLATION PROCEDURE MUST BE PERFORMED AS
WRITTEN WITHOUT ANY MODIFICATION TO PROVIDE THE FULL BENEFIT OF THE
OPTIONAL UPGRADE.
REFER TO THE ATTACHMENT III FOUND ON THE PTS WEBSITE TO VIEW VIDEO CLIPS OF
CERTAIN REPAIR STEPS.
IMPORTANT NOTES
CHECKOFF EACH ITEM AS YOU INSPECT IT, THEN ANSWER WHETHER THE ORIGINAL
INSTALLATION WAS DONE PROPERLY. IF ANY CORRECTIONS WERE REQUIRED, LIST
THEM IN THE SPACE PROVIDED.
ANY DISCREPANCIES TO THE 02B02 INSTALLATION PROCEDURES MUST BE
CORRECTED.
THIS DOCUMENT SHOULD BE SIGNED BY BOTH THE SERVICING TECHNICIAN AND THE
SERVICE MANAGER AND BE MAINTAINED IN THE DEALER'S VEHICLE SERVICE FILE,
STAPLED TO THE HARD COPY OF THE REPAIR ORDER.
HAVE A COPY OF THE ORIGINAL 02B02 ATTACHMENT III AVAILABLE FOR REFERENCE
DURING THIS INSPECTION PROCEDURE.
1992 THROUGH 1997 CVPI MODELS ARE NOT INVOLVED IN THIS FOLLOW-UP INSPECTION
PROCEDURE BECAUSE EVAPORATIVE EMISSIONS CANISTER MOUNTING MODIFICATIONS
ARE NOT PART OF THE UPGRADE KIT FOR THOSE MODEL YEARS.
INSPECTION
1. Evaporative Emissions Canister Inspection
WARNING:
DO NOT LEAVE BOLTS AND J-NUTS IN PLACE. THE RIVETS ARE INTENDED TO REPLACE
CANISTER BOLTS AND J-NUTS. THEY ARE NOT UTILIZED TO STRENGTHEN THE
MECHANICAL CONNECTION BETWEEN THE Z-BRACKET AND THE EVAPORATIVE
EMISSIONS CANISTER MOUNTING FLANGE. USING RIVETS OTHER THAN THE SUPPLIED
HIGH CLAMP-LOAD RIVETS CAN JEOPARDIZE THE REPAIR.
NOTE:
Field audits have revealed portions of this repair are not being performed properly. Listed here are
examples of what was found:
^ Bolts and J-nuts still installed - rivets installed (correctly or incorrectly)
^ Bolts and J-nuts still installed - rivets NOT installed
^ Only J-nuts still installed - rivets installed
^ Wrong number of rivets installed
^ Rivets not properly spaced along Z-bracket
^ Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to
evap canister)
If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will
need to be drilled out to allow removal of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3730
J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02
Attachment III.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3731
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3732
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3733
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3734
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3735
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3736
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3737
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade
> Page 3738
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications
EGR Electronic Vacuum Regulator Solenoid: Specifications
EGR Vacuum Regulator Solenoid Nuts 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3743
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
The EGR vacuum regulator solenoid uses input from the powertrain control module to change the
EGR valve operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3744
EGR Electronic Vacuum Regulator Solenoid: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the connector.
4. Remove the vacuum hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3745
5. Remove the two nuts and the solenoid electric vacuum regulator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation
EGR Tube: Description and Operation
The EGR valve to exhaust manifold tube:
^ connects the exhaust manifold to the EGR valve
^ has two tubes connecting to the EGR transducer for EGR flow monitoring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > EGR Valve - EGR Tube
EGR Tube: Service and Repair EGR Valve - EGR Tube
REMOVAL
1. Disconnect the differential pressure feedback EGR hoses.
2. Disconnect the EGR tube.
3. Remove the two bolts the EGR valve and the gasket.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3751
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3752
EGR Tube: Service and Repair EGR Valve Tube
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Remove the cables from the intake manifold shield.
4. Remove the bolts and the intake manifold shield.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3753
5. Remove the nut at the EGR valve. 6. Raise the vehicle.
7. Remove the nut at the exhaust manifold. 8. Lower the vehicle.
9. Remove the vacuum lines from the differential pressure feedback valve.
10. Remove the vacuum lines from the tube.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > EGR Valve - EGR Tube > Page 3754
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications
EGR Valve: Specifications
EGR Valve Bolts 18-22 Nm
EGR Valve to Exhaust Manifold Tube Fittings 35-45 Nm
EGR Valve NGV 20 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 3758
EGR Valve: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the resonator.
3. Remove the vacuum lines.
4. Remove the cables from the intake manifold shield.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 3759
5. Remove the bolts from the intake manifold shield.
6. Remove EGR valve to exhaust manifold tube.
7. Remove the bolts and the EGR valve.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 3760
1. To install, reverse the removal procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3764
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3765
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3766
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV
Valve Hose > Component Information > Service and Repair
PCV Valve Hose: Service and Repair
REMOVAL
1. Remove the engine appearance cover.
2. Remove the idle air control tube from the air cleaner outlet tube.
3. Remove the crankcase ventilation tube at the air cleaner outlet tube.
4. Remove the crankcase ventilation tube at the valve cover.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV
Valve Hose > Component Information > Service and Repair > Page 3771
1. To install, reverse the removal procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Service and Repair
Positive Crankcase Ventilation Valve: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Remove the Positive Crankcase Ventilation (PVC) valve from the grommet.
4. Remove the Positive Crankcase Ventilation (PVC) valve from the crankcase vent connector and
hose.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Page 3775
5. Remove the crankcase vent connector and hose from the throttle body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR 5-7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3780
Pressure Feedback Exhaust Sensor: Description and Operation
The EGR transducer:
^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube
^ sends an EGR flow rate signal to the powertrain control module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3781
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Remove the appearance cover.
2. Loosen the clamp and remove the engine air cleaner tube.
3. Disconnect the engine control sensor wiring.
4. Remove the two hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3782
5. Remove the two nuts and the differential pressure feedback EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Pressure
Fuel Pressure: Specifications Fuel Pressure
Fuel Pressure
Fuel Rail Pressure 105 - 130 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Pressure > Page 3788
Fuel Pressure: Specifications Volume
Flow .....................................................................................................................................................
................................................................. 160 lbs/hr
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3793
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3794
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3795
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3796
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3797
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3798
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3799
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3800
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3801
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3802
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3803
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3804
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3805
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3806
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3807
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3808
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3809
6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3810
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3811
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3812
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3813
8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3814
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications
Idle Speed: Specifications Idle Speed
Idle Speed
Hot Idle 790-815 rpm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Accelerator Pedal: Specifications
Accelerator Pedal and Shaft to Dash Panel Nuts 15-20 Nm
Accelerator Controls Bracket Bolts 5-7 Nm
Accelerator Cable Bracket Bolts 8-12 Nm
Accelerator Cable Bracket-to-Inatake Manifold Bolts 15-20 Nm
Accelerator Cable Housing to Dash Panel Nuts 3-4 Nm
Accelerator Cable Housing to Bracket Screw 8-12 Nm
EGR Vent Solenoid-to-Accelerator Bracket 7.6-10.4 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 3821
Accelerator Pedal: Description and Operation
The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and
shaft.
^ The accelerator pedal and shaft should travel smoothly from the idle to the Wide-Open Throttle
(WOT) positions. Hesitation on return and/or prevention of return to the idle position must not
occur.
^ Surrounding components such as wiring, hoses, sound insulator and floor covering must not
contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft.
^ The sliding inner member accelerator cable should not be lubricated and is not serviceable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Flow of Diagnosis
Accelerator Pedal: Flow of Diagnosis
NOTE: Care should be exercised when carrying out service on or around the accelerator pedal
linkage and controls.
1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which
would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may
cause binding. 3. Inspect the engine idle speed adjustment to ensure correct idle speed
specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for
excessive wear or damage. 5. If concern is not visually evident, determine the symptom and
proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Flow of Diagnosis > Page 3824
Accelerator Pedal: Initial Inspection and Diagnostic Overview
NOTE: Care should be exercised when carrying out service on or around the accelerator pedal
linkage and controls.
1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which
would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may
cause binding. 3. Inspect the engine idle speed adjustment to ensure correct idle speed
specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for
excessive wear or damage. 5. If concern is not visually evident, determine the symptom and
proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Flow of Diagnosis > Page 3825
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal and Shaft
Accelerator Pedal: Service and Repair Accelerator Pedal and Shaft
REMOVAL
1. Remove the accelerator cable from the accelerator pedal and shaft.
2. Remove the nuts and remove the accelerator pedal and shaft.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal and Shaft > Page 3828
Accelerator Pedal: Service and Repair Cable Bracket
REMOVAL
1. Remove the front engine appearance cover and the throttle return spring.
2. Disconnect the accelerator cable from the throttle body lever.
3. Remove the screw (cable to bracket) and remove the accelerator cable from the accelerator
cable bracket. 4. Remove the speed control cable.
5. Remove the spring.
6. Remove the nuts and remove the EGR vent solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal and Shaft > Page 3829
7. Remove the screws and the nut and remove the accelerator cable bracket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
REMOVAL
1. On gasoline vehicles, remove the engine appearance cover.
^ Loosen the retainer.
^ Remove the cover.
2. Remove the idle air control valve inlet tube.
3. Remove the crankcase ventilation hose.
4. Loosen the clamps and remove the air cleaner outlet tube.
NOTE: Gasoline shown, natural gas similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3834
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
1. Release the metal clips.
2. Lift the cover.
3. Remove the Air Cleaner (ACL) element.
INSTALLATION
1. To install,reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: >
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: >
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3846
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest for Mass Air Flow Sensor: >
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3847
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow
Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow
Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3853
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow
Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3854
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3855
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3856
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3857
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Technical Service Bulletins > Page 3858
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns
Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns
Article No. 98-26-2
01/04/99
FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED
DRIVEABILITY CONCERNS
FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94
TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR
LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER
1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99
TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350
1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99
VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR
1999 SUPER DUTY F SERIES
MEDIUM/HEAVY TRUCK: 1990-97 F-700
This TSB article is being republished in its entirety to expand vehicle model coverage and revise
the text.
ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard
start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These
concerns may be related to fuel volatility from winter blend fuels during winter-spring and
autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may
appear to be a fuel pump failure but may be caused by winter blend fuel.
ACTION Refer to the following text for further information.
NOTE
FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS
FROM CAVITATION WITHIN THE FUEL PUMP.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 3863
FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE
RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE.
Explain to the customer that this concern may be due to a low tank level of winter blend fuel
combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be
effective in resolving this concern. Also, advise customer to use the recommended octane grade
per their Owner Manual and not a higher grade.
BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize
easier) in the winter and lower volatility in the summer. Government mandates to improve air
quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates
(ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid
Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases
volatility while the reduction of RVP reduces volatility.
Gasoline distribution practices often do not allow branded marketers to have much control over
their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent
on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to
recommend specific brands to avoid volatility related complaints.
OTHER APPLICABLE ARTICLES: 91-8-13
SUPERSEDES: 96-5-4
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES:402000, 404000, 602300, 603300,
607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000,
614500, 623000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Page 3864
Fuel: Service Precautions
CAUTION: This vehicle is designed to use Compressed Natural Gas (CNG) as a motor fuel. Failure
to follow all applicable warnings concerning CNG may cause serious engine damage and/or
personal injury.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3870
Fuel Pressure Release: Service and Repair Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Typical Vent Stack Installation
NOTE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3871
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3872
Fuel Pressure Release: Service and Repair Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack. 6. Slowly open the bleed valve on the
Fuel Rail Pressure Test and Venting Kit and allow the contents of the fuel lines to vent to
atmosphere for one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3873
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3874
Fuel Pressure Release: Service and Repair Fuel Tank Venting - Solenoid Valves, Functions
Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3875
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3876
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3877
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3878
Fuel Pressure Release: Service and Repair
Warning
WARNING
^ THE FUEL SYSTEM OPERATES UNDER HIGH PRESSURE AND REMAINS PRESSURIZED
AFTER ENGINE SHUTDOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE
ANY FUEL-RELATED COMPONENTS ARE SERVICED. FAILURE TO RELIEVE THE FUEL
PRESSURE COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE STATUS (STUCK OPEN, STUCK CLOSED, OR GOOD) OF EACH FUEL TANK
SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM OR
PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT. FOR ADDITIONAL
INFORMATION.
^ DO NOT VENT AN ENTIRE FUEL TANK BY USING THE FUEL LINE VENTING PROCEDURE,
AS DAMAGE TO THE FUEL SUPPLY MANIFOLD SCHRADER VALVE WILL RESULT, WITH
THE POSSIBILITY OF PERSONAL INJURY OR PROPERTY DAMAGE.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR INSTALL
COMPONENTS OR PARTS NOT SPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS
AND SYSTEM CONFIGURATION THESE VEHICLES, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN
FIRE OR PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR
REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is
damaged or inoperative and a new fuel tank solenoid valve or fuel tank must be installed.
Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3879
Typical Vent Stack Installation
NOTE
^ The following venting procedures must be used when removal of the fuel tanks or fuel tank
solenoid valves is required for the installation of new fuel tanks or fuel tank solenoid valves.
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
^ The following procedures are based on the fuel tank solenoid valves status. Based on the results
of the solenoid status found, follow the appropriate procedure for either fuel tank solenoid valves
normal, stuck open or stuck closed.
^ The pressure relief procedure to be followed depends on the component(s) being serviced, what
component(s) may be damaged or inoperative, or at what point in fuel system procedures you are
referenced to this procedure. The status of the fuel tank solenoid valves is the most critical factor in
determining the proper fuel system pressure relief procedures to follow. Pressure relief procedures
are fuel line venting and fuel tank venting, with fuel tank venting having three parts depending on
fuel tank solenoid status.
^ The fuel line venting procedure is accomplished at the Schrader valve fitting on the fuel injection
supply manifold. This will vent the fuel lines from the fuel supply manifold to the fuel tank solenoids
(or the quarter-turn valve if it is closed). It is required prior to installation of any fuel system
component, since the fuel pressure regulator is not designed to backflow reliably. This procedure is
used either in conjunction with the fuel tank venting procedure to make sure of complete fuel
system pressure relief, or on its own if the fuel tank solenoid status is good or the quarter-turn valve
is closed. Any fuel system component downstream of the fuel tank solenoid valves (or the
quarter-turn valve if closed) may be serviced. This includes the fuel supply manifold and its related
components, the fuel shutoff valve solenoid, the coalescer/filter assembly, the fuel pressure
regulator, and all the fuel lines if the fuel tank solenoid status is good or the low pressure fuel lines
if the quarter-turn valve is closed.
^ The fuel tank venting procedure is accomplished at the fuel fill valve and should only be
performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is
detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override
Tool 134-OOO5O (or equivalent). Once the override tool has been used, a new fuel tank solenoid
must be installed, as the use of the override tool will destroy the solenoid valve. This procedure
must be preformed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent
any fuel tank for any reason.
^ The special tools required for these procedures are also available in a kit form that comes with all
the tools needed to service this vehicle. The kit is the Rotunda Natural Gas (NGV) Pressure Test
and Venting Kit, 134-00114.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3880
^ It is recommended that venting be performed with a vent stack. This is a typical installation only.
Any vent stack installation must be approved by local authorities.
Fuel Line Venting
1. Disconnect the battery ground cable.
2. Connect the Grounding Cable to the fuel injection supply manifold.
3. Connect the Grounding Cable to the ground rod.
4. Connect the Fuel Rail Pressure Test and Venting Kit to the fuel injection supply manifold
Schrader valve and to the Venting Hose Assembly.
NOTE: Make sure that the bleed valve on the Fuel Rail Pressure Test and Venting Kit is closed.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3881
6. Slowly open the bleed valve on the Fuel Rail Pressure Test and Venting Kit and allow the
contents of the fuel lines to vent to atmosphere for one
minute.
NOTE: If after venting the fuel lines for approximately one minute the pressure test gauge still
registers normal fuel system pressure at this point (95-125 psi).
7. Close the bleed valve on the Fuel Rail Pressure Test and Venting Kit and remove from the
vehicle.
Fuel Tank Venting - Solenoid Valves, Functions Normally
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks as necessary. Disconnect the electrical connectors and tighten the
manual lock-down jackscrews to 9 Nm (80 in lbs.) on the fuel tanks not to be vented. The vent box
on the upper fuel tank rack will need to be removed to access the upper fuel tank rack solenoid
jackscrews and individual upper fuel tank solenoid electrical connectors. If neither of the upper fuel
tanks needs to be vented, the upper fuel tank rack harness connector C421 may be disconnected
without removing the upper fuel tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3882
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Remove the fuel valve relay from the
power distribution box. 7. Construct jumper wire from 152 mm(6 inches) of 18 gauge wire and two
spade terminal ends.
8. Jumper the fuel valve relay circuit from Socket 87 to Socket 30.
NOTE: This step will supply power and open the fuel tank solenoid valves that have their electrical
connectors connected.
9. Slowly open the manual backflow valve on the fuel filler valve with a 3/16" Allen wrench.
10. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank
pressure if the fuel tank solenoid valve was
identified as functions normally.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Close the bleed valve on the Fuel Filler Neck Venting Kit and observe the gauge pressure. The
pressure should be at or near 0 kPa (psi).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3883
13. Remove the fuel tank solenoid manual lock-down valve.
14. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
15. Turn in the Manual Override Tool jackscrew until fuel flows. 16. Vent the fuel tank until the fuel
flow stops.
17. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3884
18. Perform the fuel line venting procedure.
19. Remove the Manual Override Tool from the fuel tank solenoid valve.
20. Install the fuel tank solenoid manual lock-down valve.
21. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 22. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Open
1. Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valves(s)) were identified as stuck open
as necessary. Disconnect the electrical
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3885
connectors and tighten the manual lock-down jackscrews to 9 Nm (80 in lbs) on the fuel tanks not
to be vented The vent box on the upper fuel tank rack will need to be removed to access the upper
fuel tank rack solenoid jackscrews and individual upper fuel tank solenoid electrical connectors. If
neither of the upper fuel tanks needs to be vented, the upper fuel tank rack harness connector
C421 may be disconnected without removing the upper fuel tank rack vent box.
2. Connect the Ground Cable to the ground rod.
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3886
6. Slowly open the manual backflow valve on the fuel filler valve. 7. Observe the gauge pressure of
the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid
valve was
identified as stuck open.
8. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the fuel
tank to vent to atmosphere. Venting may take in
excess of one hour.
9. Close the bleed valve on the Fuel Filler Neck Venting Kit, and observe the gauge pressure. The
pressure should be at or near 0 kPa (0 psi).
10. Remove the fuel tank solenoid manual lock-down valve.
11. Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3887
12. Turn in the Manual Override Tool jackscrew until fuel flows. 13. Open the manual bleed valve
on the Fuel Filler Neck Venting Kit and vent the fuel tank until the fuel flow stops.
14. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 15. Perform the fuel line venting procedure.
16. Remove the Manual Override Tool from the fuel tank solenoid valve.
17. Install the fuel tank solenoid manual lock~down valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3888
18. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 19. Repeat the
procedure until all affected tanks are vented.
Solenoid Valves - Stuck Closed
1. Connect the Grounding Cable to the back side of
NOTE ^
Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ Vent the individual fuel tanks that the fuel tank solenoid valve(s) were identified as stuck closed
as necessary. Disconnect the electrical connectors and tighten the manual lock-down jackscrews
to 9 Nm (80 in lbs) on the fuel tanks not to be vented. The vent box on the upper fuel tank rack will
need to be removed to access the upper fuel tank rack solenoid jackscrews and individual upper
fuel tank solenoid electrical connectors. If neither of the upper fuel tanks needs to be vented, the
upper fuel tank rack harness connector C421 may be disconnected without removing the upper fuel
tank rack vent box.
2. Connect the Grounding Cable to the ground rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3889
3. Connect the Fuel Filler Neck Venting Kit to the fuel filler valve.
NOTE: Make sure the manual bleed valve on the Fuel Filler Neck Venting Kit is closed prior to
connecting to the fuel filler valve.
4. Connect the Venting Hose Assembly to the Fuel Filler Neck Venting Kit.
5. Connect the Venting Hose Assembly to the vent stack. 6. Open the manual bleed valve on the
Fuel Filler Neck Venting Kit for one minute to bleed residual fuel system pressure. Close the
manual bleed
valve on the Fuel Filler Neck Venting Kit.
7. Remove the manual lock-down valve from the fuel tank solenoid valve of the fuel tank to be
vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3890
8. Install the Manual Override Tool into the fuel tank solenoid valve of the tank to be vented.
WARNING: MAKE SURE THE JACKSCREW IN THE MANUAL OVERRIDE TOOL IS
RETRACTED FULLY (COUNTERCLOCKWISE) PRIOR TO INSTALLATION INTO THE FUEL
TANK SOLENOID VALVE. INSTALLATION OF THE MANUAL OVERRIDE TOOL IN THE
VENTING POSITION WILL CAUSE NATURAL GAS TO BE IMMEDIATELY RELEASED WHICH
MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE.
CAUTION: The solenoid valve must be discarded after these procedures as the use of the Manual
Override Tool will destroy the solenoid valve.
9. Turn in the Manual Override Tool jackscrew until fuel flows.
10. Slowly open the manual backflow valve on the fuel filler valve and observe the gauge pressure
of the Fuel Filler Neck Venting Kit. The pressure
reading should be at tank pressure.
11. Slowly open the bleed valve on the Fuel Filler Neck Venting Kit and allow the contents of the
fuel tank to vent to atmosphere. Venting may take in
excess of one hour.
12. Vent the fuel tank until the fuel flow stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Special Tools Used While Performing Procedures > Page 3891
13. Close the manual backflow valve on the fuel filler valve when the tank contents have been
vented. 14. Perform the fuel line venting procedure.
15. Remove the Manual Override Tool from the fuel tank solenoid valve.
16. Install the fuel tank solenoid manual lock-down valve.
17. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve. 18. Repeat the
procedure until all affected tanks are vented.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications
Fuel Injector Wiring Harness: Specifications
Fuel Charging Wiring To Intake Manifold Bolts
............................................................................................................................ 8-12 Nm (71-106 In
lbs)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3896
Fuel Injector Wiring Harness: Service and Repair
REMOVAL
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Position the power steering pump out of the way. 2. Remove the air cleaner outlet tube. 3.
Disconnect the battery ground cable. 4. Remove the mounting arm and pivot shaft.
5. Disconnect the:
^ Idle Air Control (IAC) valve.
^ Throttle Position (TP) sensor.
6. Disconnect the eight ignition coils.
7. Disconnect the eight fuel injector electrical connectors.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3897
8. On natural gas engines, disconnect the temperature sensor.
9. Disconnect the fuel pressure sensor.
10. On natural gas engines, disconnect the main fuel shutoff solenoid connector.
11. Disconnect the engine bulkhead connectors
12. Disconnect the radio ignition interference capacitor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3898
13. Disconnect the LH heated oxygen sensor connector and the transmission electrical connector.
14. Disconnect the RH heated oxygen sensor connector.
15. Disconnect the EGR transducer.
16. Disconnect the Evaporative Emission (EVAP) canister purge valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3899
17. Disconnect the EGR vacuum regulator solenoid
18. Disconnect the connector.
19. Disconnect the A/C cycling switch. 20. Raise the vehicle.
21. Disconnect the Crankshaft Position (CKP) sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3900
22. Disconnect the A/C compressor.
23. Disconnect the:
^ engine oil pressure sensor.
^ Power Steering Pressure (PSP) switch.
24. Lower the vehicle. 25. Separate the fuel charging wiring from the rear of the intake manifold
and remove from the vehicle.
INSTALLATION
1. Position the fuel charging wiring in the vehicle and attach to the rear of the intake manifold. 2.
Raise the vehicle.
3. Connect the:
^ engine oil pressure sensor.
^ power steering pressure switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3901
4. Connect the A/C compressor.
5. Connect the crankshaft position sensor. 6. Install the power steering pump. 7. Lower the vehicle.
8. Connect the A/C cycling switch.
9. Connect the connector
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3902
10. Connect the EGR vacuum regulator solenoid.
11. Connect the evaporative emission canister purge valve.
12. Connect the EGR transducer.
13. Connect the RH heated oxygen sensor connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3903
14. Connect the LH heated oxygen sensor connector and the transmission electrical connectors.
15. Connect the radio ignition interference capacitor
16. Connect the engine bulkhead connectors. 17. Connect the main fuel shut-off solenoid
connector.
18. Connect the fuel pressure sensor connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Specifications > Page 3904
19. Connect the fuel temperature sensor connector.
20. Connect the eight fuel injector electrical connectors.
21. Connect the eight ignition coils.
22. Connect the:
^ idle air control valve.
^ throttle position sensor.
23. Install the mounting arm and pivot shaft. 24. Connect the battery ground cable. 25. Install the
air cleaner outlet tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) >
Component Information > Diagrams > Page 3908
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) >
Component Information > Diagrams > Page 3909
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) >
Component Information > Diagrams > Page 3910
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Driver Module (CNG) >
Component Information > Diagrams > Page 3911
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Specifications
Fuel Line Coupler: Specifications
Fuel Line Tube Nut O-ring Fittings 37 Nm
Upper Tank Assembly Vent Line Fittings 37 Nm
Fuel Line Tube Nut O-Ring Fittings to Fuel Tank Solenoid Valve fittings 90 Nm
Fuel Line Tube Nut O-ring Fittings To Fuel Pressure Regulator Fittings 54 Nm
Vapor Vent Box Bolts 9 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Specifications > Page 3915
Fuel Line Coupler: Service and Repair
Spring Lock Coupling Disconnect Tool (5/8 Inch)
Special Tools(s)
DISCONNECT
1. Relieve the fuel system pressure.
2. Remove the fuel tube Clip.
3. Install the Spring Lock Coupling Disconnect Tool.
4. Close and push the Spring Lock Coupling Disconnect Tool into the open side of the cage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Specifications > Page 3916
5. Separate the fitting.
6. Remove the Spring Lock Coupling Disconnect Tool
CONNECT
1. Push together the spring lock coupling fittings until the spring engages.
NOTE ^
Inspect and clean both coupling ends.
^ Install new O-ring seals.
^ Lubricate the O-ring seals with 5W30 engine oil meeting Ford specification WSS-M2C153-G or
equivalent prior to installation to help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Specifications
Fuel Pressure Regulator: Specifications
Fuel Pressure Regulator Shield Bolts 10 Nm
Fuel Pressure Regulator Mounting Bolts 23 Nm
Fuel Pressure Regulator/filter Assembly Mounting Bolts 10 Nm
Fuel Pressure Regulator 1/2 Inch Elbow Fitting 82 Nm
Fuel Pressure Regulator Coolant Bowl Screw 7 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Charging and Controls
Fuel Pressure Regulator: Description and Operation Fuel Charging and Controls
The fuel pressure regulator:
CAUTION: Use O-rings that are made of special fuel-resistant material. Use of ordinary O-rings
can cause the fuel system to leak. Do not reuse O-rings.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Charging and Controls > Page 3922
^ maintains a constant fuel pressure throughout the fuel system and to the fuel injector.
^ is spring-loaded and operated by the intake manifold vacuum.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Charging and Controls > Page 3923
Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator - Coalescer/Filter
Assembly
Natural gas vehicles are equipped with a fuel pressure regulator-coalescer/filter assembly. The
coalescer/filter assembly separates, filters and stores any contamination and moisture found in the
fuel system, preventing moisture from entering the engine. The filter can be disassembled to
service the filter element. The drain plug on the bottom of the housing allows the draining of water
that has accumulated in the fuel system. The filter should be drained at regular intervals, such as
each oil change. The fuel pressure regulator is a single stage pressure reducing regulator which
takes the natural gas from tank pressure of 1,379 to 20,685 kPa (200 to 3,000 psi) and regulates it
to engine fuel injector pressure of 724 to 862 kPa (105 to 125 psi). When reducing the pressure,
the fuel temperature drops significantly, causing extremely cold temperatures of -177°C (-160°F)
that may damage fuel system components as well as causing water vapor present in the fuel to
condense and freeze, plugging up the fuel system. Engine coolant is circulated to the fuel pressure
regulator to prevent this by warming the fuel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Page 3924
Fuel Pressure Regulator: Service and Repair
REMOVAL
WARNING
^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS
PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM,
OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM
COMPONENTS TO AVOID POSSIBLE INJURY.
1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Raise the
vehicle.
4. Remove the bolts and remove the fuel pressure regulator shield.
5. Remove the pressure regulator/filter assembly connections.
1 Remove the fuel line tube nut fittings.
2 Clamp off the fuel pressure regulator heater hoses and disconnect the hose clamps from the
pressure regulator.
6. Remove the four bolts securing the pressure regulator/filter assembly to the frame rail and
remove the assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Page 3925
7. Remove the fitting from the coalescer/filter to the fuel pressure regulator.
8. Remove the fuel pressure regulator retaining bolts and remove the regulator.
9. To remove the fuel pressure regulator coolant bowl, remove the screw and remove the coolant
bowl.
INSTALLATION
NOTE
^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural
gas use are identified with a yellow stripe.
^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help
seal and ease the installation.
^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench.
The use of a torque wrench adapter will alter the effective torque of the torque wrench being used.
To correct the effective torque, a torque multiplication conversion must be used.
^ After installation is complete, perform the Fuel System Leak Test procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Page 3926
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Pressure
Fuel Pressure: Specifications Fuel Pressure
Fuel Pressure
Fuel Rail Pressure 105 - 130 psi
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Pressure > Page 3932
Fuel Pressure: Specifications Volume
Flow .....................................................................................................................................................
................................................................. 160 lbs/hr
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Valve Relay <-->
[Fuel Pump Relay] > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Valve Relay <-->
[Fuel Pump Relay] > Component Information > Locations > Page 3936
Fuel Valve Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Valve Relay <-->
[Fuel Pump Relay] > Component Information > Locations > Page 3937
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Customer Interest for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard
Start/DTC's Set/Low Power
Fuel Rail: Customer Interest CNG Fuel System - Hard Start/DTC's Set/Low Power
Article No. 03-20-6
10/13/03
^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND
5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L
ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150
ISSUE
Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector
performance, resulting from fuel quality. The conditions (in approximate order of their occurrence)
include:
^ Loss Of Power At Heavy Load
^ DTC Codes For Lean Fuel
^ Rough Idle
^ Hard Start
^ Plugged Catalytic Converter
^ No Start
NOTE
THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE
DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER.
ACTION The root cause of these conditions may be due to either excessive or insufficient
carryover compressor oil from the CNG fill station.
Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of
10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous
fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the
injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the
injector is opened, but may delay opening or prevent an injector from opening at all. The deposit
may increase over time and may further delay the injector opening time. Insufficient oil (less than
10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to
open the injector, especially when cold. In either case, the customer may first notice a loss of
power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel
logic adjustment range for injector pulse width is exceeded.
Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector
partially or completely shut and cause a hard start or no start. A hard start and temporary rough
idle when cold is caused by some of the injectors being marginally functional at the start, and the
other injectors becoming functional as they warm up from. engine heat and soften the oil deposit
enough to release the stuck pintle.
A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely
to form injector deposits than either type alone. Vehicles that fill from many stations are more likely
to exhibit the conditions. The oil type may also change if a station compressor is serviced or
replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly
evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has
collected in a tank can still remain available to mix even after the compressor oil has been
changed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Customer Interest for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard
Start/DTC's Set/Low Power > Page 3946
SERVICE PROCEDURE
Different actions are required according to the cause and severity of the conditions exhibited. The
actions to correct an insufficient oil situation are different than the actions to correct an excessive
oil situation.
Customers reporting the conditions listed above may determine their situation by some quick
checks on the vehicle.
EVIDENCE OF INSUFFICIENT OIL INCLUDES:
^ No oil film on fill station nozzle outlet or vehicle fill receptacle.
^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl.
^ A dry coalescing filter element.
EVIDENCE OF EXCESSIVE OIL INCLUDES:
^ Heavy oil film on station nozzle outlet and vehicle fill receptacle.
^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the
element.
^ Fully oil-soaked coalescing element.
^ Liquid oil found in fuel tanks or lines opened for other service.
Fill stations that derive compressed natural gas from liquefied natural gas should have an oil
injection system. The extremely cold temperature of liquefied natural gas literally "freezes out"
lubricants and these lubricants need to be replaced after the gas returns to its vapor phase.
Customers operating their own fill stations (usually fleet customers) should routinely check that all
installed equipment is operating properly and is serviced at the intervals recommended by the
component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate
filters, and coalescing filters. A fill station may have many filters at different points in the flow
stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet,
and the dispenser. A particulate filter that becomes clogged will indicate its condition by high
differential pressures or reduced total flow. A coalescing filter that is not drained often enough can
fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream
components with no obvious indication at the filter. A fill station technician draining a pressurized
coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble,
again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than
normal due to poor sealing at the piston rings. A fill station maintenance routine should include
recording the oil volume drained from downstream filters. This record can be used to compare the
oil volume added to the compressor. This will reveal compressor wear and the associated
maintenance requirements due to this wear.
Customers who maintain their own vehicles should consider measuring and recording the oil level
found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in
several vehicles in a short period of time may indicate that a fueling station used by those vehicles
requires service to reduce its compressor oil carryover.
Fleet customers should inquire about the maintenance practices of the fill stations they use.
For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty
Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter
bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil
in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in
the fuel does not affect the filter element life, so the element should be replaced at the normal
30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil.
It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush
Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel
injectors to return to their normal function. In some fuel environments it may be necessary to
perform this cleaning on a regular basis.
NOTE
IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE
APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3
FOR THE INJECTOR CLEANING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Customer Interest for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System - Hard
Start/DTC's Set/Low Power > Page 3947
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System Hard Start/DTC's Set/Low Power
Fuel Rail: All Technical Service Bulletins CNG Fuel System - Hard Start/DTC's Set/Low Power
Article No. 03-20-6
10/13/03
^ DRIVEABILITY - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND
5.4L ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
^ ENGINE - DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES - 4.6L AND 5.4L
ENGINE - ROUGH IDLE, HARD START OR NO START WHEN COLD - LOSS OF POWER LEAN FUEL DTC'S - RESTRICTED CATALYTIC CONVERTER
FORD: 1996-2003 CROWN VICTORIA 1997-2003 E SERIES, F-150
ISSUE
Some dedicated CNG vehicles may exhibit various driveability conditions due to a loss of injector
performance, resulting from fuel quality. The conditions (in approximate order of their occurrence)
include:
^ Loss Of Power At Heavy Load
^ DTC Codes For Lean Fuel
^ Rough Idle
^ Hard Start
^ Plugged Catalytic Converter
^ No Start
NOTE
THE HARD START AND NO START TYPICALLY WILL OCCUR AT THE FIRST START OF THE
DAY AND DURING THE FIRST COLD DAYS OF FALL OR WINTER.
ACTION The root cause of these conditions may be due to either excessive or insufficient
carryover compressor oil from the CNG fill station.
Excessive carryover compressor oil is oil greater than Ford's recommended concentration levels of
10 to 80 Parts Per Million (PPM). Oil can then be carried to the injectors as a mist in the gaseous
fuel stream or as a liquid film on the. inner walls of the fuel rail. The liquid oil can collect inside the
injector and then form a semi-solid deposit over time. The deposits do not restrict fuel flow once the
injector is opened, but may delay opening or prevent an injector from opening at all. The deposit
may increase over time and may further delay the injector opening time. Insufficient oil (less than
10 PPM) may lead to wear and roughening of the injector pintle, Increasing the force required to
open the injector, especially when cold. In either case, the customer may first notice a loss of
power, rough idle, and overheated catalysts. A lean DTC code will be set when the adaptive fuel
logic adjustment range for injector pulse width is exceeded.
Either a large oil deposit, or severe wear from insufficient oil in cold conditions can hold the injector
partially or completely shut and cause a hard start or no start. A hard start and temporary rough
idle when cold is caused by some of the injectors being marginally functional at the start, and the
other injectors becoming functional as they warm up from. engine heat and soften the oil deposit
enough to release the stuck pintle.
A mixture of the two types of CNG fill station compressor oils (mineral and synthetic) is more likely
to form injector deposits than either type alone. Vehicles that fill from many stations are more likely
to exhibit the conditions. The oil type may also change if a station compressor is serviced or
replaced. It is suspected that liquid oil can collect in fill station and vehicle storage tanks and slowly
evaporate into the gaseous fuel over several months' time. Therefore, oil of one type that has
collected in a tank can still remain available to mix even after the compressor oil has been
changed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System Hard Start/DTC's Set/Low Power > Page 3953
SERVICE PROCEDURE
Different actions are required according to the cause and severity of the conditions exhibited. The
actions to correct an insufficient oil situation are different than the actions to correct an excessive
oil situation.
Customers reporting the conditions listed above may determine their situation by some quick
checks on the vehicle.
EVIDENCE OF INSUFFICIENT OIL INCLUDES:
^ No oil film on fill station nozzle outlet or vehicle fill receptacle.
^ No liquid oil found in the bottom of the high-pressure coalescing filter bowl.
^ A dry coalescing filter element.
EVIDENCE OF EXCESSIVE OIL INCLUDES:
^ Heavy oil film on station nozzle outlet and vehicle fill receptacle.
^ Liquid oil in the high-pressure coalescing filter bowl over the level of the white spacer under the
element.
^ Fully oil-soaked coalescing element.
^ Liquid oil found in fuel tanks or lines opened for other service.
Fill stations that derive compressed natural gas from liquefied natural gas should have an oil
injection system. The extremely cold temperature of liquefied natural gas literally "freezes out"
lubricants and these lubricants need to be replaced after the gas returns to its vapor phase.
Customers operating their own fill stations (usually fleet customers) should routinely check that all
installed equipment is operating properly and is serviced at the intervals recommended by the
component supplier. This includes gas dryers, compressors, oil and odorant injectors, particulate
filters, and coalescing filters. A fill station may have many filters at different points in the flow
stream, such as at the compressor inlet and outlet, dryer inlet and outlet, the storage tank outlet,
and the dispenser. A particulate filter that becomes clogged will indicate its condition by high
differential pressures or reduced total flow. A coalescing filter that is not drained often enough can
fill up with liquids (oil and/or water) and then act as a source of oil contamination for downstream
components with no obvious indication at the filter. A fill station technician draining a pressurized
coalescing filter too rapidly can rupture the internal element with no obvious indication of trouble,
again allowing oil to pass downstream. A compressor that needs to be rebuilt can use more oil than
normal due to poor sealing at the piston rings. A fill station maintenance routine should include
recording the oil volume drained from downstream filters. This record can be used to compare the
oil volume added to the compressor. This will reveal compressor wear and the associated
maintenance requirements due to this wear.
Customers who maintain their own vehicles should consider measuring and recording the oil level
found in the coalescent filter bowl during routine maintenance. An increase in the oil level found in
several vehicles in a short period of time may indicate that a fueling station used by those vehicles
requires service to reduce its compressor oil carryover.
Fleet customers should inquire about the maintenance practices of the fill stations they use.
For vehicles known to have excessive oil in their fuel, Ford recommends using the Severe Duty
Maintenance Interval of 15,000 miles (25,000 kilometers) to inspect and drain the coalescent filter
bowl. Vehicles maintained at this interval and still found to repeatedly have one inch or more of oil
in the coalescent filter bowl may require a more frequent maintenance interval. The amount of oil in
the fuel does not affect the filter element life, so the element should be replaced at the normal
30,000 miles (50,000 kilometers) interval even if the fuel is known to have excessive oil.
It may also be necessary to clean the CNG fuel injectors using Motorcraft PM- 5 Power Flush
Injector Fluid. Refer to TSB # 03-18-03 for this service procedure. This cleaning will allow the fuel
injectors to return to their normal function. In some fuel environments it may be necessary to
perform this cleaning on a regular basis.
NOTE
IT MAY ALSO BE NECESSARY TO CLEAN OR REPLACE THE FUEL INJECTORS IF THE
APPROPRIATE MAINTENANCE INTERVAL IS NOT ADHERED TO. REFER TO TSB # 03-18-3
FOR THE INJECTOR CLEANING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: 03-18-3 WARRANTY STATUS: INFORMATION ONLY
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 03-20-6 > Oct > 03 > CNG Fuel System Hard Start/DTC's Set/Low Power > Page 3954
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3955
Fuel Rail: Specifications
Fuel Injection Supply Manifold Temperature Sensor 39-42 Nm
Fuel Injection Supply Manifold to Intake Manifold 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3956
Fuel Rail: Description and Operation
The fuel injection supply manifold:
^ delivers fuel to the fuel injector.
^ receives fuel from the fuel supply line.
^ provides mounting surfaces for the fuel temperature sensor and the fuel pressure sensor.
^ provides mounting surface for the main fuel shut-off solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3957
Fuel Rail: Testing and Inspection
LEAK TEST - FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTORS
Special Tool(s)
1. Remove the fuel valve relay from the power distribution box.
NOTE: After the vehicle has soaked for several hours, a very slight natural gas smell may emanate
from within the intake manifold and intake air system. This is normal, as the fuel injectors leak
down from the fuel injection supply manifold to the intake manifold over several hours.
2. Construct jumper wire from 152 mm (6 inches) of 18 gauge wire and two spade terminal ends.
3. Jumper the fuel valve relay circuit from Socket 87 to Socket 30. 4. Remove the jumper wife. 5.
Install the fuel valve relay into the power distribution box. 6. Check the spring lock coupling and the
fuel injection supply manifold to fuel injector connections for leaks using the Combustible Gas
Detector
(part of NGV Pressure Test and Venting Kit)
7. If a leak is detected, verify the connection is engaged properly, then retest. 8. If the leak remains,
repair as necessary and retest.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3958
Fuel Rail: Service and Repair
REMOVAL
WARNING
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Disconnect the battery ground cable. 2. Relieve the fuel pressure. 3. Disconnect the fuel lines. 4.
Remove the throttle body. 5. On gasoline engines, remove the EGR valve to exhaust manifold
tube. 6. Remove the drive belt.
7. Disconnect the fuel temperature sensor connector.
8. Disconnect the fuel pressure sensor connector.
9. Disconnect the connector.
10. Disconnect the main fuel shut-off solenoid connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3959
11. Remove the bolts and the generator mounting bracket.
12. Remove the bolts.
13. Unclip the accelerator cable and the speed control actuator cable from the two crash brackets
and position out of the way.
14. Separate the LH heated oxygen sensor and the transmission electrical connector from the
bracket at the rear of the cylinder head.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3960
15. Remove the nut-bolt and the wiring bracket
16. Disconnect the vacuum lines and position out of the way.
NOTE: On natural gas vehicles, there are no EGR vacuum connections.
17. Disconnect the eight fuel injector electrical connectors.
18. Disconnect the crankcase ventilation tube and position out of the way.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3961
19. On gasoline engines, disconnect the vacuum line.
20. On gasoline engines, disconnect the vacuum line from the Evaporative Emission (EVAP)
canister purge valve.
21. On gasoline engines, disconnect the EGR vacuum regulator solenoid. 22. Remove the bolt and
the stud. 23. Remove the crash bracket. 24. Remove the studs. 25. Remove the fuel injection
supply manifold and the fuel injectors as an assembly.
INSTALLATION
1. Lubricate the fuel injector pockets with clean engine oil XO-10W30-QSP or DSP or equivalent
meeting Ford specification WSS-MZC153-G, to
aid installation.
CAUTION: Use O-rings that are made of special fuel resistant material. Use of ordinary O-rings can
cause the fuel system to leak. Do not reuse O-rings.
NOTE: Natural gas fuel injectors are identified by an aqua cap.
2. Install the fuel injection supply manifold and the fuel injectors as an assembly 3. Torque fuel
injection supply manifold bolts to specification. 4. Install the studs. 5. Install the crash bracket. 6.
Install the bolt and the stud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3962
7. On gasoline engines, connect the EGR vacuum regulator solenoid.
8. On gasoline engines, connect the vacuum line to the evaporative emission canister purge valve.
9. On gasoline engines, connect the vacuum line.
10. Connect the crankcase ventilation tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3963
11. Connect the eight fuel injector electrical connectors.
12. Connect the vacuum lines.
NOTE: On natural gas engines there are no EGR vacuum connections.
13. Install the fuel supply retaining bracket nut and bolt.
14. Attach the LH heated oxygen sensor connector and the transmission electrical connector to the
bracket at the rear of the cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3964
15. Clip the accelerator cable and the speed control actuator cable to the two crash brackets.
16. Install the bolts.
17. Install the generator mounting bracket and tighten the bolts. 18. Connect the main fuel shut-off
solenoid connector.
19. Connect the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Technical Service Bulletins > Page 3965
20. Connect the fuel pressure sensor connector.
21. Connect the fuel temperature sensor connector. 22. Install the drive belt. 23. On gasoline
engines, install the EGR valve to exhaust manifold tube. 24. Install the throttle body. 25. Connect
the fuel lines. 26. Connect the battery ground cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03
> Fuel System (CNG) - Fill Valve Leaks
Fuel Receptacle (CNG): Customer Interest Fuel System (CNG) - Fill Valve Leaks
Article No. 03-11-7
06/09/03
DRIVEABILITY - CNG - POSSIBLE FUEL LEAK AT FILL VALVE - FILL VALVE SERVICE PART
REVISIONS - CNG VEHICLES ONLY
FORD: 1996-2003 CROWN VICTORIA
Article 03-4-9 is being republished in its entirety to update the Service Part numbers due to a
Supplier change.
ISSUE On some CNG (Compressed Natural Gas) Crown Victoria vehicles, a possible fuel leak
may occur at the fuel fill valve. When replacing the fill valve, the previous practice for these
vehicles was to service failed CNG till valves with a flange assembly consisting of a flange, a fill
valve, a rubber boot, and a dust cap. That practice needlessly complicated production and service
part numbering across different vehicle lines since the same fill valve in different flange assemblies
was numbered differently. The bypass feature for CNG fill valves is no longer required due to
revisions in service procedures and equipment. A new fill valve supplier has been approved for
Crown Victoria.
ACTION The previous service part (flange assembly) will be separated into a fill valve, a flange,
and a rubber boot. One fill valve with one Part Number will then be used to service many vehicles.
Different flanges will be released to service each vehicle. Most repairs will be for the fill valve only
and the existing flange and boot can remain installed in the vehicle. A replacement dust cap is
provided with each fill valve service part and is also available separately.
SERVICE PROCEDURE
NOTE
THIS SERVICE PROCEDURE SHOULD ONLY BE PERFORMED BY AN AUTHORIZED CNG
FUEL SYSTEM TECHNICIAN.
NOTE
FOLLOW ALL CNG FUEL SYSTEM SAFETY PROCEDURES LISTED IN THE APPROPRIATE
WORKSHOP MANUAL
Fill Valve Removal:
1. Perform the fuel line venting portion of the Fuel System Pressure Release procedure in
Workshop Manual Section 310-00B. (For older vehicles equipped with a manual back flow valve,
refer to appropriate Model Year Workshop Manual).
2. Remove rubber boot and four (4) retaining screws behind flange and set aside.
3. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve.
4. Remove the flange retaining nut and discard.
NOTE
USE A 1-3/8 IN DEEP-WALL SOCKET ON RETAINING NUT.
5. Remove the fuel filler valve from the mounting flange.
Fill Valve Installation:
NOTE
LUBRICATE 0-RING SEAL ON FILL VALVE WITH 5W-30 ENGINE OIL. WHEN TIGHTENING
THE FUEL LINES TO THE FILLER VALVE, A TORQUE WRENCH ADAPTOR MUST BE USED.
REFER TO WORKSHOP MANUAL SECTION 310-00B.
NOTE
FUEL TEST LEAK PROCEDURE (REFER TO SECTION 310-00B IN WORK SHOP MANUAL)
1. Remove dust caps and flange retaining nut from new fill valve.
2. Install fuel fill valve in mounting flange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03
> Fuel System (CNG) - Fill Valve Leaks > Page 3974
3. Install and torque flange retaining nut to 24-30 N.m (18-22 lb-ft).
NOTE
USE A 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON RETAINING NUT.
Parts List
4. Install rubber boot over back end of till valve behind flange with bulge facing forward.
5. Install and torque four (4) retaining screws to 2.8-4.0 N.m (25-35 lb-in).
6. Install the fuel line to the fuel filler valve and torque fitting nut to 38-57 N.m (28-42 lb-ft) using a
backup wrench.
7. Check for leaks at the fuel line fitting (refer to Workshop Manual).
Flange Removal:
Remove fill valve (see previous procedure).
1. Remove four (4) bolts holding flange.
2. Retain fill valve dust cap.
Flange Installation:
1. Hold flange in fuel fill bucket so four (4) screw holes align with four (4) holes in bucket with sharp
end of central depression pointing to the rear.
2. Install four (4) bolts and torque to 2.7-3.3 N.m (25-30 lb-in) with grommet of dust cap under lower
front bolt.
NOTE
USE A 1-3/8 IN DEEP-WALL SOCKET ON BRASS RETAINING NUT. USE 1-1/4 IN OR 32 MM
DEEP-WALL SOCKET ON STEEL RETAINING NUT.
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-4-9 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 404000, 490000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Receptacle (CNG): > 03-11-7 > Jun > 03
> Fuel System (CNG) - Fill Valve Leaks > Page 3975
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Receptacle (CNG): >
03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks
Fuel Receptacle (CNG): All Technical Service Bulletins Fuel System (CNG) - Fill Valve Leaks
Article No. 03-11-7
06/09/03
DRIVEABILITY - CNG - POSSIBLE FUEL LEAK AT FILL VALVE - FILL VALVE SERVICE PART
REVISIONS - CNG VEHICLES ONLY
FORD: 1996-2003 CROWN VICTORIA
Article 03-4-9 is being republished in its entirety to update the Service Part numbers due to a
Supplier change.
ISSUE On some CNG (Compressed Natural Gas) Crown Victoria vehicles, a possible fuel leak
may occur at the fuel fill valve. When replacing the fill valve, the previous practice for these
vehicles was to service failed CNG till valves with a flange assembly consisting of a flange, a fill
valve, a rubber boot, and a dust cap. That practice needlessly complicated production and service
part numbering across different vehicle lines since the same fill valve in different flange assemblies
was numbered differently. The bypass feature for CNG fill valves is no longer required due to
revisions in service procedures and equipment. A new fill valve supplier has been approved for
Crown Victoria.
ACTION The previous service part (flange assembly) will be separated into a fill valve, a flange,
and a rubber boot. One fill valve with one Part Number will then be used to service many vehicles.
Different flanges will be released to service each vehicle. Most repairs will be for the fill valve only
and the existing flange and boot can remain installed in the vehicle. A replacement dust cap is
provided with each fill valve service part and is also available separately.
SERVICE PROCEDURE
NOTE
THIS SERVICE PROCEDURE SHOULD ONLY BE PERFORMED BY AN AUTHORIZED CNG
FUEL SYSTEM TECHNICIAN.
NOTE
FOLLOW ALL CNG FUEL SYSTEM SAFETY PROCEDURES LISTED IN THE APPROPRIATE
WORKSHOP MANUAL
Fill Valve Removal:
1. Perform the fuel line venting portion of the Fuel System Pressure Release procedure in
Workshop Manual Section 310-00B. (For older vehicles equipped with a manual back flow valve,
refer to appropriate Model Year Workshop Manual).
2. Remove rubber boot and four (4) retaining screws behind flange and set aside.
3. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve.
4. Remove the flange retaining nut and discard.
NOTE
USE A 1-3/8 IN DEEP-WALL SOCKET ON RETAINING NUT.
5. Remove the fuel filler valve from the mounting flange.
Fill Valve Installation:
NOTE
LUBRICATE 0-RING SEAL ON FILL VALVE WITH 5W-30 ENGINE OIL. WHEN TIGHTENING
THE FUEL LINES TO THE FILLER VALVE, A TORQUE WRENCH ADAPTOR MUST BE USED.
REFER TO WORKSHOP MANUAL SECTION 310-00B.
NOTE
FUEL TEST LEAK PROCEDURE (REFER TO SECTION 310-00B IN WORK SHOP MANUAL)
1. Remove dust caps and flange retaining nut from new fill valve.
2. Install fuel fill valve in mounting flange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Receptacle (CNG): >
03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks > Page 3981
3. Install and torque flange retaining nut to 24-30 N.m (18-22 lb-ft).
NOTE
USE A 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON RETAINING NUT.
Parts List
4. Install rubber boot over back end of till valve behind flange with bulge facing forward.
5. Install and torque four (4) retaining screws to 2.8-4.0 N.m (25-35 lb-in).
6. Install the fuel line to the fuel filler valve and torque fitting nut to 38-57 N.m (28-42 lb-ft) using a
backup wrench.
7. Check for leaks at the fuel line fitting (refer to Workshop Manual).
Flange Removal:
Remove fill valve (see previous procedure).
1. Remove four (4) bolts holding flange.
2. Retain fill valve dust cap.
Flange Installation:
1. Hold flange in fuel fill bucket so four (4) screw holes align with four (4) holes in bucket with sharp
end of central depression pointing to the rear.
2. Install four (4) bolts and torque to 2.7-3.3 N.m (25-30 lb-in) with grommet of dust cap under lower
front bolt.
NOTE
USE A 1-3/8 IN DEEP-WALL SOCKET ON BRASS RETAINING NUT. USE 1-1/4 IN OR 32 MM
DEEP-WALL SOCKET ON STEEL RETAINING NUT.
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-4-9 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 404000, 490000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Receptacle (CNG) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Receptacle (CNG): >
03-11-7 > Jun > 03 > Fuel System (CNG) - Fill Valve Leaks > Page 3982
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid >
Component Information > Description and Operation
Fuel Shut-off Solenoid: Description and Operation
The fuel shut-off solenoid:
^ is normally closed.
^ opens when the key is in the run or start position.
^ shuts off the fuel supply if the vehicle is shut off or if the inertia fuel shut-off is triggered.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Specifications
Fuel Supply Line: Specifications
Fuel Line Retainer Bolts 9 Nm
Flexible Tube Retaining Nuts 12 Nm
Fuel Supply Retaining Bracket Nut and Bolt 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > High Pressure Line
Fuel Supply Line: Service and Repair High Pressure Line
REMOVAL
WARNING
^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS
PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM,
OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM
COMPONENTS TO AVOID POSSIBLE INJURY.
1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Raise the
vehicle.
4. Remove the bolts and remove the pressure regulator shield.
5. Remove the fuel tank fuel line tube nut fitting at the quarter-turn valve and the filler valve fuel line
tube nut fitting at the coalescer/filter "T" fitting.
6. Remove the fuel tank fuel outlet line tube nut fitting at tank No.3 solenoid "T" fitting.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > High Pressure Line > Page 3991
7. Remove the filler valve fuel line tube nut fitting at the rear of the filler valve.
8. Remove the bolts from the fuel line retainers and remove the high pressure fuel lines.
INSTALLATION
NOTE
^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural
gas use are identified with a yellow stripe.
^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help
seal and ease the installation.
^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench.
The use of a torque wrench adapter will alter the effective torque of the torque wrench being used.
To correct the effective torque, a torque multiplication conversion must be used.
^ After installation is complete, perform the Fuel System Leak Test procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > High Pressure Line > Page 3992
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > High Pressure Line > Page 3993
Fuel Supply Line: Service and Repair Low Pressure Line
Spring Lock Coupling Disconnect Tool (5/8 Inch)
Special Tool(s)
REMOVAL
WARNING
^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS
PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM,
OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM
COMPONENTS TO AVOID POSSIBLE INJURY.
1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Disconnect
the fuel line spring lock coupling from the engine fuel supply manifold. 4. Raise the vehicle. 5.
Remove the LH dual catalytic converter on dual exhaust systems.
6. Remove the bolts and remove the pressure regulator shield.
7. Remove the low pressure fuel line tube nut fitting from the pressure regulator outlet fitting.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > High Pressure Line > Page 3994
8. Remove the fuel line retaining bolts.
9. Remove the fuel line retaining bolt at the frame rail near the engine compartment. Remove the
fuel line.
INSTALLATION
NOTE
^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural
gas use are identified with a yellow stripe.
^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help
seal and ease the installation.
^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench.
The use of a torque wrench adapter will alter the effective torque of the torque wrench being used.
To correct the effective torque, a torque multiplication conversion must be used.
^ After installation is complete, perform the Fuel System Leak Test procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > High Pressure Line > Page 3995
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel System Manual Control Valve
(CNG) > Component Information > Service and Repair
Fuel System Manual Control Valve (CNG): Service and Repair
REMOVAL
WARNING
^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS
PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM,
OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM
COMPONENTS TO AVOID POSSIBLE INJURY.
1. Perform the Pressure Relief-Fuel System. 2. Disconnect the battery ground cable. 3. Raise the
vehicle.
4. Remove the bolts and remove the fuel pressure regulator shield.
5. Slowly loosen the fuel line tube nuts to allow residual pressure to vent. Remove the tube nuts
from the quarter-turn valve fittings.
6. Remove the retaining clip and remove the quarter-turn valve.
INSTALLATION
NOTE
^ Install new fuel system O-rings using approved O-rings only. O-rings that are approved for natural
gas use are identified with a yellow stripe.
^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help
seal and ease the installation.
^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench.
The use of a torque wrench adapter will alter the effective torque of the torque wrench being used.
To correct the effective torque, a torque multiplication conversion must be used.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel System Manual Control Valve
(CNG) > Component Information > Service and Repair > Page 3999
^ After installation is complete, perform the fuel system leak test procedure.
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Specifications
Fuel Filler Hose: Specifications
Fuel Filler Valve to Body Screws 3 Nm
Fuel Filler Valve Outlet Fittings 27 Nm
Fuel Filler Manual Backflow Valve 9 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Filler Valve
Fuel Filler Hose: Service and Repair Fuel Filler Valve
REMOVAL
WARNING
^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS
PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM,
OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM
COMPONENTS TO AVOID POSSIBLE INJURY.
1. Perform the Pressure Relief- Fuel System. 2. Disconnect the battery ground cable. 3. Remove
the four screws from the protective boot and position aside.
4. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve.
5. Remove the fuel filler valve retaining bolts and remove the fuel filler valve.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Filler Valve > Page 4006
1. To install, reverse the removal procedure.
NOTE ^
Install new fuel system O-ring seals with approved O-rings only. O-rings that are approved for
natural gas use are identified with a yellow stripe.
^ Lubricate the fuel system O-ring seals with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help
seal and ease the installation.
^ When tightening the fuel lines, a torque wrench adapter must be used with the torque wrench.
The use of a torque wrench adapter will alter the effective torque of the torque wrench being used.
To correct the effective torque, a torque multiplication conversion must be used.
^ After installation is complete, perform the Fuel System Leak Test procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Filler Valve > Page 4007
Fuel Filler Hose: Service and Repair Fuel Filler Valve Filter
Filter Remover/Installer Tool
Special Tool(s)
REMOVAL
1. Remove the fuel filler valve. 2. Position the fuel filler valve in a vise.
3. Remove the fitting from the fuel filler valve.
4. Using the Filter Remover/Installer Tool 134-OO115 (part of NGV pressure and venting kit
134-00114), turn the fuel filler valve filter
counterclockwise to remove.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: After installation is complete, perform the Fuel System Leak Test procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair
Fuel Tank Mounting Straps: Service and Repair
REMOVAL
1. Perform Pressure Relief-Fuel System.
WARNING ^
DO NOT MODIFY THE FUEL SYSTEM CONFIGURATION OR COMPONENTS OR INSTALL
NEW COMPONENTS WITH PARTS NOT SPECIFICALLY DESIGNED FOR USE WITH
NATURAL GAS. FORD MOTOR COMPANY HAS SPECIFICALLY DESIGNED THE MATERIALS,
COMPONENTS AND SYSTEM CONFIGURATION FOR THE THIS VEHICLE, AND EACH
PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE
OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION
THAT COULD RESULT IN FIRE, PERSONAL INJURY OR PROPERTY DAMAGE.
^ THE FUEL SYSTEM WILL REMAIN PRESSURIZED AFTER ENGINE SHUTDOWN. THIS
PRESSURE MUST BE RELIEVED BEFORE SERVICING ANY PART OF THE FUEL SYSTEM,
OR PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM
COMPONENTS TO AVOID POSSIBLE INJURY.
NOTE: The support straps are part of the fuel rack assembly. The fuel tanks can be removed for
service, but a new fuel rack must be installed if there is damage to the support straps or the rack
assembly itself.
2. Remove the upper or lower fuel tank rack assembly as required. 3. On upper fuel tank rack
assemblies, remove the vapor vent box. 4. On both upper and lower fuel tank rack assemblies,
remove the fuel/vent lines as necessary.
5. Remove the bolts securing the straps together. Swing the straps outward on their hinges to
access the fuel tanks.
NOTE: If the fuel tanks are going to be re-used, mark their location relative to the support straps
with a grease pencil to insure proper alignment upon installation.
6. On the lower rack assembly, remove the two bolts securing the support straps together. Swing
the support strap up on the hinges to gain access to
the fuel tanks.
NOTE: If the fuel tanks are going to be re-used, mark their location relative with the support straps
with a grease pencil to insure proper alignment upon installation.
7. Remove the solenoid valves if necessary to remove the fuel tanks.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 4011
1. To install, reverse the removal procedure.
NOTE ^
Install new O-rings on fittings that are disconnected. Use only approved O-rings which contain a
yellow identification stripe.
^ After installation is complete, perform the Fuel System Leak Test procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Specifications
Fuel Temperature Sensor: Specifications
Fuel Tank Temperature Sensor 40 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor
REMOVAL
NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.1.
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the upper NGV fuel tank temperature sensor.
1 Disconnect the electrical connector.
2 Remove the fuel tank temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 4017
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor
REMOVAL
NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.2.
1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle.
3. Remove the lower NGV fuel tank shield upper nuts.
4. Remove the lower NGV fuel tank shield.
1 Remove the nuts.
2 Remove the lower NGV fuel tank shield.
5. Remove the lower NGV fuel tank temperature sensor.
1 Disconnect the lower NGV fuel tank temperature sensor electrical connector.
2 Remove the lower NGV fuel tank temperature sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Service and Repair > Fuel Tank Temperature (Upper) Sensor > Page 4018
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy
^ Replace the lower NGV fuel tank temperature sensor O-ring seal.
^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30
engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to
installation, to help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications
Idle Air Control Valve: Specifications
Idle Air Control Valve Bolts 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4022
Idle Air Control Valve: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Idle Air Control (IAC) valve.
4. Remove the idle air control valve hose.
5. Remove the two screws and the idle air control valve.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4023
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4032
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4033
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4034
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4035
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4036
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4037
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4038
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4039
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4040
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 >
Campaign - Inertia Switch Bracket Replacement > Page 4041
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4047
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4048
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4049
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4050
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4051
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4052
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4053
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4054
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4055
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: >
99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4056
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Page 4057
Inertia Fuel Shutoff Switch: Specifications
Inertia Fuel Shutoff Switch Screws
............................................................................................................................................................
1.0 Nm (9 in lbs)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Page 4058
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Open the luggage compartment door.
3. Disconnect the connector from the inertia fuel shutoff switch.
4. Remove the retaining screws from the inertia fuel shutoff switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > PCM Power Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4064
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4069
Fuel Injector Driver Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4070
Fuel Injector Driver Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4071
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Injector Driver Module (CNG) > Component Information > Diagrams > Page 4072
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 4076
Fuel Valve Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Valve Relay <--> [Fuel Pump Relay] > Component Information > Locations > Page 4077
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power
Relay
Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power
Relay > Page 4083
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability
Symptoms
Mass Air Flow Sensor: Customer Interest Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability
Symptoms > Page 4093
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Customer Interest for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability
Symptoms > Page 4094
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms
Mass Air Flow Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms
Article No. 98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP
FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN
VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR
LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE
LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER
1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD,
F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999
F-250 HD, SUPER DUTY F SERIES
ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability
symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.
ACTION Follow the diagnostic procedures described in the following Service Tip. The revised
diagnostic procedure is a more accurate means of diagnosing the symptoms.
SERVICE TIP
MASS AIR FLOW (MAF) DISCUSSION
MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting
compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer
function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and
under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term
Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher
air flows.
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open
loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will
actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle
applies Long Term Fuel Trim corrections that have been learned during closed loop operation.
These corrections are often lean corrections learned at lower air flows. This combination of
under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and
lack of power concerns at WOT and high loads.
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure
(BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT
(there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged
engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the
engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading
is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim
and MAF
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 4100
voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO
NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS.
Symptoms
^ Lack of Power
^ Spark Knock/Detonation
^ Buck/Jerk
^ Hesitation/Surge on Acceleration
^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory
OBDII DTCs
^ P0171, P0174 (Fuel system lean, Bank 1 or 2)
^ P0172, P0175, (Fuel system rich, Bank 1 or 2)
^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1)
^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2)
OBDI DTCs
^ 181, 189 (Fuel system lean, Bank 1 or 2)
^ 179, 188 (Fuel system rich, Bank 1 or 2)
^ 171, 172, 173 (HO2S11 lack of switching, Bank 1)
^ 175, 176, 177 (HO2S21 lack of switching, Bank 2)
^ 184, 185 (MAF higher/lower than expected)
^ 186, 187 (Injector pulse width higher/lower than expected)
NOTE:
DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET
LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO
PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC
PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME
OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE
BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Mass Air Flow Sensor: > 98-23-10 > Nov > 98 > Engine - Lean
Driveability Symptoms > Page 4101
1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea
level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524
meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is
up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz
lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic
System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric
pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the
hookup screen. Connect GP2 to the reference MAP on the following screen.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1
and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean
corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both
Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank
system has negative corrections, the MAF sensor is probably not contaminated.
3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's
30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis
(PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough
guide, the MAF sensor is over-estimating air flow at idle.
4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor
connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM
mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In
addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go
away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability
symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE
FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs
AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF
ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN
DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs
INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR.
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM,
or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and
verify that the lean driveability symptoms are gone.
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000,
614500, 614600, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Page 4102
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Bolts 4-5 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Page 4103
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Page 4104
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor.
CAUTION: Do not tamper with the MAF sensing elements located in the airflow by pass.
Tampering may result in unit failure.
NOTE: The MAF sensor module and body are calibrated and replaced as a unit.
3. Loosen the clamp and remove the air cleaner outlet tube.
4. Remove the four bolts and the mass air flow sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical
Service Bulletins > Page 4105
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Specifications
Fuel Temperature Sensor: Specifications
Fuel Tank Temperature Sensor 40 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank
Temperature (Upper) Sensor
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Upper) Sensor
REMOVAL
NOTE: The upper fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.1.
1. Remove the upper NGV fuel tank rack assembly. 2. Remove the NGV fuel tank vent box.
3. Remove the upper NGV fuel tank temperature sensor.
1 Disconnect the electrical connector.
2 Remove the fuel tank temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank
Temperature (Upper) Sensor > Page 4111
Fuel Temperature Sensor: Service and Repair Fuel Tank Temperature (Lower) Sensor
REMOVAL
NOTE: The lower fuel tank temperature sensor is also referred to as fuel tank temperature sensor
No.2.
1. Carry out the Pressure Relief Fuel Line Venting procedure. 2. Raise and support the vehicle.
3. Remove the lower NGV fuel tank shield upper nuts.
4. Remove the lower NGV fuel tank shield.
1 Remove the nuts.
2 Remove the lower NGV fuel tank shield.
5. Remove the lower NGV fuel tank temperature sensor.
1 Disconnect the lower NGV fuel tank temperature sensor electrical connector.
2 Remove the lower NGV fuel tank temperature sensor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair > Fuel Tank
Temperature (Upper) Sensor > Page 4112
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to learn the strategy
^ Replace the lower NGV fuel tank temperature sensor O-ring seal.
^ Lubricate the lower NGV fuel tank temperature sensor O-ring seal with Super Premium 5W30
engine oil XO-5W30-BSP meeting Ford specification WSS-M2C153-G or equivalent prior to
installation, to help seal and ease the installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4121
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4122
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4123
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4124
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4125
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4126
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4127
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4128
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4129
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for
Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4130
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement
Technical Service Bulletin # 99B03 Date: 990301
Campaign - Inertia Switch Bracket Replacement
99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Attachment I ^
Administrative Information
^ Refund Codes
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION
Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4136
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4137
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the
list. Give owner a copy of the Owner Letter.
Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4138
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal
processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
SERVICE PROCEDURE
1. Open trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4139
2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.
4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner
quarter panel reinforcement. Refer to Figure 2.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4140
5. Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for
installation purposes. NOTE: The inertia switch and inertia switch cover will be removed as an
assembly.
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT
disconnect inertia switch electrical connector.
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.
^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at
this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new
location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4141
9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these
locations.
11. Remove inertia switch bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4142
12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure
5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See
Figure 6. Tighten bolts to 9 Nm (6.6 lb-ft).
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2
lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4143
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4144
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4145
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4146
Inertia Fuel Shutoff Switch: Specifications
Inertia Fuel Shutoff Switch Screws
............................................................................................................................................................
1.0 Nm (9 in lbs)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4147
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Open the luggage compartment door.
3. Disconnect the connector from the inertia fuel shutoff switch.
4. Remove the retaining screws from the inertia fuel shutoff switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications
Throttle Body: Specifications
Throttle Body-to-Intake Manifold Spacer 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 4154
Throttle Body: Description and Operation
The throttle body:
^ controls air supply to the upper intake manifold by positioning the throttle plate.
^ connects the accelerator cable and, if equipped the speed control actuator cable to the throttle
plate.
^ is not adjustable.
^ cannot be cleaned.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 4155
Throttle Body: Service and Repair
REMOVAL
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: The throttle body bore and plate area have a special coating and cannot be cleaned.
NOTE: Gasoline engine shown, natural gas similar.
1. Remove the air cleaner outlet tube.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
3. Disconnect the accelerator cable and the speed control actuator cable.
4. Disconnect the throttle return spring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 4156
5. Remove the four bolts and the throttle body
NOTE: Discard the Throttle Body (TB) gasket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications
Throttle Cable/Linkage: Specifications
Accelerator Cable Bracket Bolts 8-12 Nm
Accelerator Cable Bracket to Intake Manifold Bolts 15-20 Nm
Accelerator Cable Housing to Bracket Screw 8-12 Nm
Accelerator Cable Housing to Dash Panel Nuts 3-4 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 4160
Throttle Cable/Linkage: Description and Operation
The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and
shaft.
^ The accelerator pedal and shaft should travel smoothly from the idle to the Wide-Open Throttle
(WOT) positions. Hesitation on return and/or prevention of return to the idle position must not
occur.
^ Surrounding components such as wiring, hoses, sound insulator and floor covering must not
contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft.
^ The sliding inner member accelerator cable should not be lubricated and is not serviceable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 4161
Throttle Cable/Linkage: Service and Repair
REMOVAL
1. Remove the front engine appearance cover and the throttle return spring.
2. Disconnect the accelerator cable from the throttle body lever.
3. Remove the screw (cable to bracket) and remove the accelerator cable from the accelerator
cable bracket.
4. Remove the accelerator cable from the clip.
5. Remove the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 4162
6. Disconnect the accelerator cable from the accelerator pedal and shaft.
7. Remove the accelerator cable retainer. 8. Pull the cable through the dash panel and remove
from the vehicles.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Service and Repair
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine appearance cover.
3. Disconnect the electrical connector from the Throttle Position (TP) sensor.
4. Remove the screws and the throttle position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 4177
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 4181
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 4182
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 4183
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips
Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips
TSB 05-22-8
11/14/05
WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE
MISFIRE OR ROUGH RUNNING
FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005
Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006
E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006
Escape 2002-2005 Explorer 2005-2006 Escape Hybrid
LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS
1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego
2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 04-16-01 to update the vehicle applications and model years.
NOTE
FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs
RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED.
ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS
Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition
problems (be sure to rule out coil primary circuit issues). Once the above steps have been
completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure
outlined in this TSB can isolate the difference between a coil or spark plug problem.
SERVICE PROCEDURE
The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and
help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through
1-800-ROTUNDA.
The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire
diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not
random misfires. Random misfires have a different root cause and are not covered by this TSB.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4188
Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes
for a cylinder specific misfire could be fuel, spark, or mechanical problems.
Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools
for misfire diagnosis:
^ Self-test (Check for codes first)
Power Balance (Identify the cylinder of concern)
^ Relative Compression (Rule out a possible mechanical issue)
^ Fuel (Make sure fuel injectors are not restricted)
^ Ignition (Make sure spark plugs and coils are working properly)
^ Oscilloscope (Detailed signal analysis)
NOTE
USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR
DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED.
If there is a self-test code identifying a particular cylinder then you just need to determine if it is a
fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative
Compression to rule out any mechanical issues. If there is no self-test code and the customer
concern is a miss, proceed to Step 1.
Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4189
The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to
proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque
the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be
reproduced during brake torque, select Relative Compression under Powertrain on WDS before
going on a road test to rule out mechanical problems. If Relative Compression shows a problem
then the base engine issue must be serviced. If Relative Compression results are good (Figure 3),
road test under as many different driving conditions as possible until the miss occurs on Power
Balance. Some misses may be very intermiffent so be patient and concentrate on steady load
conditions. Once a cylinder dropout is identified proceed to Step 2.
Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test)
Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel
Pressure/Leakdown test, select Injector flow to isolate
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4190
a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to
Step 3.
Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test)
Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both
duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in
Figure 5 and Figure 6.
NOTE
LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA
TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING.
THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4191
MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO
STEP 4.
If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values
displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system.
Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark
plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the
issue is the coil or the spark plug.
Step 4: (Select Toolbox, then Oscilloscope)
WARNING
SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY
FROM THE END OF THE COIL THAT SUPPLIES THE SPARK.
SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so
the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around
the hard shell of the coil to help keep the coil propped up and stable.
CAUTION
THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING
THIS PROCEDURE.
Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route
the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise
interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the
cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will
show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands
and tools away from the end of the coil that supplies the spark.
COP Stress Test Procedure:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4192
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4193
Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select
COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil
being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is
sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark
to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All
settings are pre-configured and no adjustments are necessary. Compare the waveform you get
with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform
is similar to Figure 7 the coil is working correctly. Suspect the spark plug.
Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to
Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in
Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak
signal in Figure 7.
Figure 9 shows a more dramatic fault in the peak failure.
Most root causes of misfire issues can be identified quickly using the steps outlined above. Some
misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox.
OTHER APPLICABLE ARTICLES: 05-13-4
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 4194
Ignition Coil: Diagrams
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Locations
Ignition Control Module: Locations
The ignition control module is integrated within the powertrain control module. It is not a separately
replaceable component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Locations > Page 4198
Ignition Control Module: Description and Operation
PURPOSE
- The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM).
The ICM receives engine position and speed information from within the crankshaft position sensor
and desired spark advance information from the PCM.
OPERATION
- The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use
within The PCM.
- The PCM uses this information to determine which ignition coil to fire, calculating the turn
ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Specifications > Page 4202
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Locations
Ignition Control Module: Locations
The ignition control module is integrated within the powertrain control module. It is not a separately
replaceable component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Locations > Page 4207
Ignition Control Module: Description and Operation
PURPOSE
- The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM).
The ICM receives engine position and speed information from within the crankshaft position sensor
and desired spark advance information from the PCM.
OPERATION
- The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use
within The PCM.
- The PCM uses this information to determine which ignition coil to fire, calculating the turn
ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 4212
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor.
3. Remove the bolt and the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolt 8-12 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 4216
Crankshaft Position Sensor: Description and Operation
The crankshaft position sensor:
^ is a variable reluctance sensor.
^ provides base timing and crankshaft speed (rpm) information to the Powertrain Control Module
(PCM).
^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 4217
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the accessory drive belt.
3. Raise and support the vehicle.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH
MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
4. Disconnect the electrical connector from the Crankshaft Position (CKP) sensor. 5. Remove the
two bolts and position the A/C compressor out of the way.
6. Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 4218
7. Remove the crankshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available
Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available > Page 4224
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available > Page 4225
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available > Page 4226
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available > Page 4227
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available > Page 4228
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4229
Ignition Switch Lock Cylinder: Specifications
Lock Cylinder Housing Screws ............................................................................................................
.................................................... 22 Nm (16 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional
Ignition Switch Lock Cylinder: Service and Repair Functional
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4232
Ignition Switch Lock Cylinder: Service and Repair Non-Functional
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4233
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the steering column lock housing bearing and steering column lock gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
1. Install the steering column lock gear and bearing.
^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification
ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing
bearing.
^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three
o'clock position. Rotate it counterclockwise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4234
2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install
the steering wheel.
4. Install the ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Nut 20-30 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Specifications > Page 4238
Knock Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the lower intake manifold.
3. Disconnect the electrical connector from the Knock Sensor (KS).
4. Remove the nut and the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap > Page 4243
Spark Plug: Specifications
Spark Plugs 20 Nm
Spark Plug Gap 1.32-1.42 mm
Spark Plug Type AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4244
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
............................................................... AWSF-32P
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4245
Spark Plug: Description and Operation
The spark plugs:
^ change a high voltage pulse into a spark which ignites the fuel and air mixture.
^ originally equipped on the vehicle have a platinum-enhanced active electrode for long life.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4246
Spark Plug: Service and Repair
REMOVAL
1. Remove the ignition coil.
2. Remove the spark plugs.
NOTE: Use compressed air to remove any debris from the spark plug well before removing the
spark plugs.
3. Inspect the spark plugs for a gap bridged.
^ Check for deposit build-up closing the gap between electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
4. Inspect for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4247
5. Inspect for carbon fouling, identified by black, dry, fluffy carbon deposits on insulator tips,
exposed shell surfaces and electrodes. This is caused
by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive
idling. ^
Clean the spark plug.
6. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
7. Inspect for pre-ignition,
^ identified by melted electrodes and possibly a damaged insulator. Metallic deposits on the
insulator indicate engine damage, which may be caused by incorrect ignition timing, wrong type of
fuel or the installation of a heli-coil insert in place of the spark plug threads.
^ Install a new spark plug.
8. Inspect for overheating, identified by a white or light gray insulator with small black or gray-brown
spots with bluish-burnt appearance of
electrodes. This can be caused by engine overheating, the wrong type of fuel, loose spark plugs,
spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4248
^ Install a new spark plug.
9. Inspect for fused spot deposits, identified by melted or spotty deposits resembling bubbles or
blisters. These are caused by sudden acceleration.
^ Clean the spark plug.
10. Adjust the spark plug gap as required.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure
Regulating Solenoid, A/T] > Component Information > Service and Repair
Electronic Pressure Control Solenoid: Service and Repair
Removal
1. Remove the manual control lever.
CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
2. Disconnect the molded lead frame from the solenoids.
1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC).
3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead
inter-connector.
3. Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure
Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 4255
2. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector.
^ Connect the Electronic Pressure Control (EPC) solenoid.
^ Connect the Torque Converter Clutch (TCC).
^ Connect the shift solenoid SSA and SSB.
3. Install the manual control lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] >
Component Information > Specifications
Shift Lock Actuator: Specifications
Retaining Screw ..................................................................................................................................
.................................................... 9 Nm (80 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] >
Component Information > Specifications > Page 4259
Shift Lock Actuator: Service and Repair
Removal
1. Remove the steering column.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced in the field.
3. Remove the insert plate from the shift lock actuator.
^ Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Description and Operation
Overdrive Indicator Lamp: Description and Operation
The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when
the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the
automatic transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the transmission range
selector lever in the OD position.
^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate
two detents counterclockwise (OD position).
3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever.
4. Center the pointer in the middle of the OD position.
^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent
to detent and compare with transmission settings.
^ Re-adjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative > Page 4281
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock
- Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock
- Inoperative > Page 4287
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 4291
Transmission Mode Switch: Description and Operation
The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of
the transmission control selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF
will illuminate on the transmission control selector lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 4292
Transmission Mode Switch: Service and Repair
TRANSMISSION MODE SWITCH
Removal
1. Remove the Transmission Control (TC) switch.
1. Remove the TC switch cover. 2. Remove the TC switch.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 4296
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 4297
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 4298
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 4299
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications > Page 4303
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed
Technical Service Bulletin # 99B04 Date: 990301
Campaign - PCM Reflashing, Reduced Top Speed
99B04
OWNER NOTIFICATION PROGRAM
Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed > Page 4312
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed > Page 4313
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give owner a copy of the
Owner Letter. Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed > Page 4314
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS Parts Ordering Information
No parts are required for this program.
CLAIMS PREPARATION Enter using DWE.
Use code information shown below:
^ Program Code: 99B04
^ Labor Operation: B04B
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE
INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998
SERVICE PROCEDURE
1. Check the PCM calibration as follows:
^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information.
^ Cross reference data to information below to determine the calibration level.
2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD
(current R level) using one of the following two (2) methods:
^ Service Bay Diagnostic System (SBDS).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed > Page 4315
^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with
Rotunda flash cable (007-00531) and Rotunda flash card (007-00532).
3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P
& A Code, date of repair and the recall program type and program number as shown below.
4. Apply label to clear area of the upper radiator support.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed > Page 4316
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top
Speed > Page 4317
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While
Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While
Accelerating > Page 4323
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While
Accelerating > Page 4324
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 00-8-1 > Apr > 00 > PCM - Rough Idle On Cold Engine
Start Up
PROM - Programmable Read Only Memory: Customer Interest PCM - Rough Idle On Cold Engine
Start Up
Article No. 00-8-1
DATE: 04/17/2000
IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT
THROUGH 7/15/1998
FORD: 1998-1999 CROWN VICTORIA
ISSUE A rough idle approximately 20 seconds after a cold engine start-up may occur on some
vehicles. This condition will usually occur after a 12 hour soak, with ambient temperatures above
10° C (50 ° F). This may be due to a Powertrain Control Module (PCM) calibration
ACTION Perform normal diagnostics in accordance with the Powertrain Control/Emissions
Diagnosis (PC/ED) Service Manual, then reprogram the PCM with the latest level calibration using
World Diagnostic System (WDS) or New Generation Star (NGS) Tester Refer to the following PCM
Reprogramming Information Chart to identify the appropriate calibration.
Recalibration Information
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and
emmission warranty coverage.
OPERATION DESCRIPTION TIME
000801A reprogram powertrain 0.4 HR
control module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE 12A650
42
OASIS CODES: 608000, 608400, 609000, 609400.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At
Extension Housing
PROM - Programmable Read Only Memory: Customer Interest A/T - 4R70W Vibration/Fluid Leak
At Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At
Extension Housing > Page 4333
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At
Extension Housing > Page 4334
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation
Above 90 Degrees F.
PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock/Detonation
Above 90 Degrees F.
Article No. 99-15-5
07/26/99
SPARK KNOCK - DURING ACCELERATION IN AMBIENT TEMPERATURES GREATER THAN
32 DEGREES C (90 DEGREES F) - VEHICLES BUILT THROUGH 1/1999
FORD: 1999 CROWN VICTORIA
MERCURY: 1999 GRAND MARQUIS
ISSUE A light spark knock/detonation may occur while accelerating in ambient temperatures
greater than 32°C (90°F). This may be caused by the Powertrain Control Module (PCM) calibration.
ACTION Reprogram the PCM. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Perform normal diagnostics in accordance with the 1999 Powertrain Control/Emissions
Diagnosis (PC/ED) Service Manual and repair as necessary.
2. If no problem was found, reprogram the PCM with the latest level calibration using Service Bay
Diagnostic System (SBDS) or New Generation Star (NGS) Tester. Refer to the following PCM
Reprogramming Information Chart to identify the appropriate calibration.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: 98-25-18
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation
Above 90 Degrees F. > Page 4339
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991505A Reprogram Powertrain 0.6 Hr.
Control Module (PCM)
991505B If PC/ED Diagnostics Are Required, Use "A" Time Per The Warranty And Policy Manual
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4345
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4346
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4351
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4352
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
00-8-1 > Apr > 00 > PCM - Rough Idle On Cold Engine Start Up
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Rough Idle On
Cold Engine Start Up
Article No. 00-8-1
DATE: 04/17/2000
IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT
THROUGH 7/15/1998
FORD: 1998-1999 CROWN VICTORIA
ISSUE A rough idle approximately 20 seconds after a cold engine start-up may occur on some
vehicles. This condition will usually occur after a 12 hour soak, with ambient temperatures above
10° C (50 ° F). This may be due to a Powertrain Control Module (PCM) calibration
ACTION Perform normal diagnostics in accordance with the Powertrain Control/Emissions
Diagnosis (PC/ED) Service Manual, then reprogram the PCM with the latest level calibration using
World Diagnostic System (WDS) or New Generation Star (NGS) Tester Refer to the following PCM
Reprogramming Information Chart to identify the appropriate calibration.
Recalibration Information
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and
emmission warranty coverage.
OPERATION DESCRIPTION TIME
000801A reprogram powertrain 0.4 HR
control module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE 12A650
42
OASIS CODES: 608000, 608400, 609000, 609400.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 4R70W
Vibration/Fluid Leak At Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4361
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4362
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F.
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark
Knock/Detonation Above 90 Degrees F.
Article No. 99-15-5
07/26/99
SPARK KNOCK - DURING ACCELERATION IN AMBIENT TEMPERATURES GREATER THAN
32 DEGREES C (90 DEGREES F) - VEHICLES BUILT THROUGH 1/1999
FORD: 1999 CROWN VICTORIA
MERCURY: 1999 GRAND MARQUIS
ISSUE A light spark knock/detonation may occur while accelerating in ambient temperatures
greater than 32°C (90°F). This may be caused by the Powertrain Control Module (PCM) calibration.
ACTION Reprogram the PCM. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Perform normal diagnostics in accordance with the 1999 Powertrain Control/Emissions
Diagnosis (PC/ED) Service Manual and repair as necessary.
2. If no problem was found, reprogram the PCM with the latest level calibration using Service Bay
Diagnostic System (SBDS) or New Generation Star (NGS) Tester. Refer to the following PCM
Reprogramming Information Chart to identify the appropriate calibration.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: 98-25-18
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. > Page 4367
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991505A Reprogram Powertrain 0.6 Hr.
Control Module (PCM)
991505B If PC/ED Diagnostics Are Required, Use "A" Time Per The Warranty And Policy Manual
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed
Technical Service Bulletin # 99B04 Date: 990301
Campaign - PCM Reflashing, Reduced Top Speed
99B04
OWNER NOTIFICATION PROGRAM
Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4372
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4373
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give owner a copy of the
Owner Letter. Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4374
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS Parts Ordering Information
No parts are required for this program.
CLAIMS PREPARATION Enter using DWE.
Use code information shown below:
^ Program Code: 99B04
^ Labor Operation: B04B
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE
INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998
SERVICE PROCEDURE
1. Check the PCM calibration as follows:
^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information.
^ Cross reference data to information below to determine the calibration level.
2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD
(current R level) using one of the following two (2) methods:
^ Service Bay Diagnostic System (SBDS).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4375
^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with
Rotunda flash cable (007-00531) and Rotunda flash card (007-00532).
3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P
& A Code, date of repair and the recall program type and program number as shown below.
4. Apply label to clear area of the upper radiator support.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4376
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4377
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4383
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4384
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Technical Service Bulletin # 00-10-3 Date: 000515
PCM - Engine Spark Knock While Accelerating
Article No. 00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90
DEGREES F)
FORD: 1998-1999 CROWN VICTORIA
MERCURY: 1998-1999 GRAND MARQUIS
ISSUE A spark knock may occur while accelerating in ambient temperatures greater than 32C
(90F) on some vehicles. This may be caused by an inoperative cooling fan and/or too much spark
advance commanded by the calibration when operating in high ambient temperatures.
ACTION Check the operation of the high and low speed cooling fans, and if necessary reprogram
the Powertrain Control Module (PCM) and/or adjust the timing using NGS. Refer to the following
Service Procedure for details.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
001003A Reprogram Powertrain 1.3 Hrs.
Control Module (PCM), Perform Octane Adjust Procedure And Check Operation Of Cooling Fans
(Also Includes Time To Test Drive To Check For Spark knock)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4389
Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present,
procedure to next Step.
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS
CONCERN. THE SOFTWARE OCTANE ADJUST PROCEDURE CAN BE PERFORMED ONLY
ONCE, AND IS NOT REVERSIBLE.
14. Perform the Software Octane Adjust Procedure using NGS, the current service card and the
flash cable. Make sure that you adjust the timing and not the octane rating as follows in the
following Steps.
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.
18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4390
24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
00-8-1 > Apr > 00 > PCM - Rough Idle On Cold Engine Start Up
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Rough Idle On
Cold Engine Start Up
Article No. 00-8-1
DATE: 04/17/2000
IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT
THROUGH 7/15/1998
FORD: 1998-1999 CROWN VICTORIA
ISSUE A rough idle approximately 20 seconds after a cold engine start-up may occur on some
vehicles. This condition will usually occur after a 12 hour soak, with ambient temperatures above
10° C (50 ° F). This may be due to a Powertrain Control Module (PCM) calibration
ACTION Perform normal diagnostics in accordance with the Powertrain Control/Emissions
Diagnosis (PC/ED) Service Manual, then reprogram the PCM with the latest level calibration using
World Diagnostic System (WDS) or New Generation Star (NGS) Tester Refer to the following PCM
Reprogramming Information Chart to identify the appropriate calibration.
Recalibration Information
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and
emmission warranty coverage.
OPERATION DESCRIPTION TIME
000801A reprogram powertrain 0.4 HR
control module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE 12A650
42
OASIS CODES: 608000, 608400, 609000, 609400.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 4R70W
Vibration/Fluid Leak At Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4399
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4400
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F.
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark
Knock/Detonation Above 90 Degrees F.
Article No. 99-15-5
07/26/99
SPARK KNOCK - DURING ACCELERATION IN AMBIENT TEMPERATURES GREATER THAN
32 DEGREES C (90 DEGREES F) - VEHICLES BUILT THROUGH 1/1999
FORD: 1999 CROWN VICTORIA
MERCURY: 1999 GRAND MARQUIS
ISSUE A light spark knock/detonation may occur while accelerating in ambient temperatures
greater than 32°C (90°F). This may be caused by the Powertrain Control Module (PCM) calibration.
ACTION Reprogram the PCM. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Perform normal diagnostics in accordance with the 1999 Powertrain Control/Emissions
Diagnosis (PC/ED) Service Manual and repair as necessary.
2. If no problem was found, reprogram the PCM with the latest level calibration using Service Bay
Diagnostic System (SBDS) or New Generation Star (NGS) Tester. Refer to the following PCM
Reprogramming Information Chart to identify the appropriate calibration.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES: 98-25-18
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99-15-5 > Jul > 99 > Engine - Spark Knock/Detonation Above 90 Degrees F. > Page 4405
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991505A Reprogram Powertrain 0.6 Hr.
Control Module (PCM)
991505B If PC/ED Diagnostics Are Required, Use "A" Time Per The Warranty And Policy Manual
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4411
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4412
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed
Technical Service Bulletin # 99B04 Date: 990301
Campaign - PCM Reflashing, Reduced Top Speed
99B04
OWNER NOTIFICATION PROGRAM
Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4417
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4418
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give owner a copy of the
Owner Letter. Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4419
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS Parts Ordering Information
No parts are required for this program.
CLAIMS PREPARATION Enter using DWE.
Use code information shown below:
^ Program Code: 99B04
^ Labor Operation: B04B
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE
INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998
SERVICE PROCEDURE
1. Check the PCM calibration as follows:
^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information.
^ Cross reference data to information below to determine the calibration level.
2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD
(current R level) using one of the following two (2) methods:
^ Service Bay Diagnostic System (SBDS).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4420
^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with
Rotunda flash cable (007-00531) and Rotunda flash card (007-00532).
3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P
& A Code, date of repair and the recall program type and program number as shown below.
4. Apply label to clear area of the upper radiator support.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4421
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
99B04 > Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4422
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] >
Component Information > Service and Repair
Electronic Pressure Control Solenoid: Service and Repair
Removal
1. Remove the manual control lever.
CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
2. Disconnect the molded lead frame from the solenoids.
1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC).
3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead
inter-connector.
3. Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] >
Component Information > Service and Repair > Page 4429
2. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector.
^ Connect the Electronic Pressure Control (EPC) solenoid.
^ Connect the Torque Converter Clutch (TCC).
^ Connect the shift solenoid SSA and SSB.
3. Install the manual control lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications
Shift Lock Actuator: Specifications
Retaining Screw ..................................................................................................................................
.................................................... 9 Nm (80 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications
> Page 4433
Shift Lock Actuator: Service and Repair
Removal
1. Remove the steering column.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced in the field.
3. Remove the insert plate from the shift lock actuator.
^ Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service
and Repair
Electronic Pressure Control Solenoid: Service and Repair
Removal
1. Remove the manual control lever.
CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
2. Disconnect the molded lead frame from the solenoids.
1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC).
3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead
inter-connector.
3. Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service
and Repair > Page 4442
2. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector.
^ Connect the Electronic Pressure Control (EPC) solenoid.
^ Connect the Torque Converter Clutch (TCC).
^ Connect the shift solenoid SSA and SSB.
3. Install the manual control lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications
Shift Lock Actuator: Specifications
Retaining Screw ..................................................................................................................................
.................................................... 9 Nm (80 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4446
Shift Lock Actuator: Service and Repair
Removal
1. Remove the steering column.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced in the field.
3. Remove the insert plate from the shift lock actuator.
^ Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift
Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift
Article No. 99-18-5
09/06/99
^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH
DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT
BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION
^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN
3/15/1997 AND 12/31/1998
FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER,
F-150, F-250 LD
LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR
MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER
This TSB article is being republished in its entirety to revise the Service Procedure.
ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on
some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some
vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster
heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when
compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking
2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782.
ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large
diameter 2-3 accumulator seal. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs.
2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester
during the 2-3 shift.
3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS
Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop
within 1-2 seconds, continue to Step 4.
4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3
accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the
appropriate Service or Workshop Manual for replacement procedure.
PART NUMBER PART NAME
F7AZ-7H292-AB Accumulator Piston
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 99-1-3
WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991805A Replace Accumulator 1.8 Hrs.
Piston Per Service
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4458
Procedure (Includes Diagnosis)
991805B Diagnosis Only (Do Not 0.8 Hr.
Use With Operation A)
DEALER CODING
CONDITION
BASIC PART NO CODE
7H292 42
OASIS CODES: 501000, 504000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep >
99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift
Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3
Upshift
Article No. 99-18-5
09/06/99
^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH
DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT
BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION
^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN
3/15/1997 AND 12/31/1998
FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER,
F-150, F-250 LD
LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR
MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER
This TSB article is being republished in its entirety to revise the Service Procedure.
ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on
some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some
vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster
heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when
compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking
2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782.
ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large
diameter 2-3 accumulator seal. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs.
2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester
during the 2-3 shift.
3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS
Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop
within 1-2 seconds, continue to Step 4.
4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3
accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the
appropriate Service or Workshop Manual for replacement procedure.
PART NUMBER PART NAME
F7AZ-7H292-AB Accumulator Piston
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 99-1-3
WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991805A Replace Accumulator 1.8 Hrs.
Piston Per Service
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep >
99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4464
Procedure (Includes Diagnosis)
991805B Diagnosis Only (Do Not 0.8 Hr.
Use With Operation A)
DEALER CODING
CONDITION
BASIC PART NO CODE
7H292 42
OASIS CODES: 501000, 504000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > 1-2 Accumulator
Accumulator: Service and Repair 1-2 Accumulator
Special Tools
Removal
1. Use (A) Servo Piston Remover Replacer to compress the 1-2 accumulator cover and remove the
(B) accumulator piston retaining ring.
NOTE: Note the location of the 1-2 accumulator springs for reference during assembly.
2.
1. Remove the 1-2 accumulator cover. 2. Remove the lower 1-2 accumulator spring. 3. Remove the
accumulator piston. 4. Remove the upper 1-2 accumulator spring.
Installation
1. Install the 1-2 accumulator.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > 1-2 Accumulator > Page 4467
1. Install the 1-2 accumulator upper spring. 2. Install the accumulator piston. 3. Install the 1-2
accumulator lower spring. 4. Install the cover and seal assembly.
2. Use (A) Servo Piston Remover Replacer to install the (B) accumulator piston retaining ring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > 1-2 Accumulator > Page 4468
Accumulator: Service and Repair 2-3 Accumulator
Removal
1. Remove the main control valve body.
2. Remove the 2-3 accumulator piston retainer.
3. Remove the accumulator piston and spring.
Installation
1. Install the 2-3 accumulator assembly.
1. Install the accumulator piston. 2. Install the accumulator piston spring. 3. Install the accumulator
spring retainer.
2. Install the main control valve body.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 4469
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Overdrive Servo
Band Apply Servo: Service and Repair Overdrive Servo
Special Tools
Removal
1. Remove the main control valve body.
NOTE: If the tool is not available, extreme care must be taken. Spring pressure will force overdrive
servo piston assembly out of case. Case bore damage may result from trying to pry on overdrive
servo internal retaining ring.
2. Use (A) Servo Piston Remover/Replacer to compress the servo spring then remove the (B)
overdrive servo retaining ring.
3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring.
Installation
1. Install the overdrive servo piston assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Overdrive Servo > Page 4477
1. Install the overdrive servo piston return spring. 2. Install the overdrive servo piston assembly.
2. Use (A) Servo Piston Remover/Replacer Tool to install the (B) overdrive servo piston retaining
ring. 3. Install the main control valve body.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Overdrive Servo > Page 4478
Band Apply Servo: Service and Repair Reverse Servo Assembly
Special Tools
Removal
1. Remove the main control valve body.
2. Use the Servo Piston Remover/Replacer to remove the reverse band servo retaining ring.
1. Compress the servo spring. 2. Remove the reverse band servo retaining ring.
NOTE: The length of the rod attached to the piston is graded for three different lengths. Therefore,
they should not be installed in any transmission other than the transmission from which they were
removed.
3. Remove the (A) reverse band servo cover , (B) reverse band servo piston and rod and (C)
reverse band servo spring.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Overdrive Servo > Page 4479
NOTE: ^
This is not an ordinary installation procedure and does not compensate for band wear.
^ Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
1. Install the reverse servo piston and return spring.
^ Do not install the piston cover.
2. Install the Servo Piston Selection Tool and tighten the band apply bolt.
3. Attach the Dial Indicator With Bracketry.
^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial
indicator.
4. Loosen the bolt until the piston stops against the tool.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Overdrive Servo > Page 4480
5. Verify the amount of piston travel on the dial indicator is within specification.
6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B)
two groove or (C) three groove, to bring the servo
piston travel within specification.
7. Remove the dial indicator and servo selection tool.
8. Install the proper servo piston assembly spring and the reverse servo piston cover and seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Overdrive Servo > Page 4481
9. Use the Servo Piston Remover/Replacer to install the reverse servo retaining ring.
1. Compress the servo spring. 2. Install the reverse band servo retaining ring.
10. Install the main control valve body.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Page 4482
Band Apply Servo: Tools and Equipment
Special Tools
Special Tools
Special Tool(s)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch, A/T
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch, A/T > Page 4487
Clutch: Specifications
Clearance 0.062 - 0.85 in
Snap Ring Thickness 0.050 - 0.054
0.064 - 0.068
0.078 - 0.082
0.092 - 0.096
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch, A/T > Page 4488
Clutch: Specifications
Clearance 0.050 - 0.094 in
Snap Ring Thickness 0.060 - 0.064 in.
0.074 - 0.078 in.
0.088 - 0.092 in.
0.102 - 0.106 in.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch, A/T > Page 4489
Clutch: Specifications
Clearance 1.643 - 1.677 in
Snap Ring Thickness 0.067 - 0.071 in
0.077 - 0.081 in
0.087 - 0.091 in
0.097 - 0.101 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch, A/T > Page 4490
Clutch: Specifications
Clearance 0.040 - 0.060 in
Snap Ring Thickness 0.060 - 0.064 in
0.074 - 0.078 in
0.088 - 0.092 in
0.102 - 0.106 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Service and Repair
Automatic Transmission Dipstick - Dipstick Tube: Service and Repair
Removal
1. Remove the bolt.
2. Remove the fluid filler tube.
Installation
1. Follow removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed
Technical Service Bulletin # 99B04 Date: 990301
Campaign - PCM Reflashing, Reduced Top Speed
99B04
OWNER NOTIFICATION PROGRAM
Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed > Page 4502
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed > Page 4503
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give owner a copy of the
Owner Letter. Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed > Page 4504
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS Parts Ordering Information
No parts are required for this program.
CLAIMS PREPARATION Enter using DWE.
Use code information shown below:
^ Program Code: 99B04
^ Labor Operation: B04B
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE
INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998
SERVICE PROCEDURE
1. Check the PCM calibration as follows:
^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information.
^ Cross reference data to information below to determine the calibration level.
2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD
(current R level) using one of the following two (2) methods:
^ Service Bay Diagnostic System (SBDS).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed > Page 4505
^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with
Rotunda flash cable (007-00531) and Rotunda flash card (007-00532).
3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P
& A Code, date of repair and the recall program type and program number as shown below.
4. Apply label to clear area of the upper radiator support.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed > Page 4506
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Recalls: > 99B04 > Mar > 99 > Campaign - PCM Reflashing,
Reduced Top Speed > Page 4507
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W
Vibration/Fluid Leak At Extension Housing
Extension Housing: Customer Interest A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W
Vibration/Fluid Leak At Extension Housing > Page 4513
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W
Vibration/Fluid Leak At Extension Housing > Page 4514
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99-18-1 >
Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Extension Housing: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension
Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99-18-1 >
Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4520
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99-18-1 >
Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4521
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed
Technical Service Bulletin # 99B04 Date: 990301
Campaign - PCM Reflashing, Reduced Top Speed
99B04
OWNER NOTIFICATION PROGRAM
Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4526
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4527
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give owner a copy of the
Owner Letter. Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4528
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS Parts Ordering Information
No parts are required for this program.
CLAIMS PREPARATION Enter using DWE.
Use code information shown below:
^ Program Code: 99B04
^ Labor Operation: B04B
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE
INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998
SERVICE PROCEDURE
1. Check the PCM calibration as follows:
^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information.
^ Cross reference data to information below to determine the calibration level.
2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD
(current R level) using one of the following two (2) methods:
^ Service Bay Diagnostic System (SBDS).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4529
^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with
Rotunda flash cable (007-00531) and Rotunda flash card (007-00532).
3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P
& A Code, date of repair and the recall program type and program number as shown below.
4. Apply label to clear area of the upper radiator support.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4530
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Extension Housing: > 99B04 >
Mar > 99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4531
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99-18-1 > Sep
> 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Extension Housing: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At Extension
Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99-18-1 > Sep
> 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4537
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99-18-1 > Sep
> 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 4538
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed
Technical Service Bulletin # 99B04 Date: 990301
Campaign - PCM Reflashing, Reduced Top Speed
99B04
OWNER NOTIFICATION PROGRAM
Certain 1999 Crown Victoria w/Police Package - Transmission Bushing Spin Out
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4544
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4545
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator
(FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give owner a copy of the
Owner Letter. Arrange with the owner for a service date.
CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6.
OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4546
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter
if an emergency repair was made away from the servicing dealer), enter using DWE:
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS Parts Ordering Information
No parts are required for this program.
CLAIMS PREPARATION Enter using DWE.
Use code information shown below:
^ Program Code: 99B04
^ Labor Operation: B04B
See Sections 5 & 6 of the ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR CROWN VICTORIA POLICE
INTERCEPTORS BUILT BEFORE NOVEMBER 20, 1998
SERVICE PROCEDURE
1. Check the PCM calibration as follows:
^ Use the N.G.S., access PCM, pick "MODULE I.D." to determine necessary information.
^ Cross reference data to information below to determine the calibration level.
2. If the calibration is not 9VNA-AAD, reflash Powertrain Control Module (PCM) to 9VNA-AAD
(current R level) using one of the following two (2) methods:
^ Service Bay Diagnostic System (SBDS).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4547
^ Service Bay Technical System (SBTS) and the New Generation STAR (NGS) Tester with
Rotunda flash cable (007-00531) and Rotunda flash card (007-00532).
3. Obtain and prepare the Authorized Modifications Label. Write the modification completed, your P
& A Code, date of repair and the recall program type and program number as shown below.
4. Apply label to clear area of the upper radiator support.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4548
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Extension Housing: > 99B04 > Mar >
99 > Campaign - PCM Reflashing, Reduced Top Speed > Page 4549
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Technical Service Bulletins > Page 4550
Extension Housing: Specifications
Extension Housing Bolts 19 - 22 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
A/T Fluid ..............................................................................................................................................
........................................................ 13.1L (13.8 Qt)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 4555
Fluid - A/T: Fluid Type Specifications
Item ......................................................................................................................................................
............................................................. Specification
Motorcraft MERCON V Automatic Transmission Fluid
................................................................................................................................... MERCON V
Note: MERCON V is not interchangeable at this time with the current MERCON service fluids.
Check the transmission dipstick to determine the correct fluid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Page 4556
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Page 4557
Fluid - A/T: Service and Repair
1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service,
such as a clutch, band, bearing, etc., is required,
the automatic transmission fluid will also have to be removed for service. At this time, the torque
converter, transmission cooler tubes must be thoroughly flushed to remove any dirt and the
oil-to-air cooler must be replaced.
The oil-to-air cooler must be replaced under the following conditions:
1. Evidence of transmission assembly or fluid contamination is found due to the following
transmission or converter failure modes:
^ major metallic failure
^ multiple clutches or clutch plate failures
2. When used under continuous or severe conditions, the transmission and torque converter should
be drained and refilled with fluid.
^ Normal Maintenance Change fluid at 48,279 km (30,000 miles).
^ Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles).
CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or
failure.
2. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for
the transmission code. 3. When filling a dry transmission and torque converter, refer to
Specifications for capacity. Check the fluid level.
Removal
1. If equipped deactivate the air suspension. 2. Disconnect the battery ground cable 3. Raise the
vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan.
5. Drain transmission fluid.
^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the
bolts.
6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket.
^ Replace transmission fluid pan gasket as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Page 4558
7. Remove torque converter housing plug.
8. Remove the torque converter drain plug and drain the torque converter.
^ Rotate the crankshaft to access the drain plug.
9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C)
magnet.
10. Flush the fluid cooler tubes. 11. Flush the torque converter.
Installation
NOTE: A new torque converter drain plug must be used.
1. Install the torque converter drain plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Page 4559
2. Install the torque converter housing plug.
CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a
small screwdriver to remove the seal. Use care not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
3. Replace fluid filter and seal as required.
4. Position the (B) pan magnet into the (A) transmission fluid pan.
NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not
damaged, the gasket should be reused.
5. Install the transmission fluid pan and gasket.
1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Page 4560
6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped reactivate
the air suspension..
NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts).
10. Fill transmission to proper fluid level.
^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent fluid
meeting Ford specification MERCON V(R).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications
Fluid Line/Hose: Specifications
Cooler Tube Nut to Case Fitting 13 ft.lb
Fluid Cooler Line Case Fittings 15 - 19 ft.lb
Fluid Cooler Tube Nut 13 - 16 ft.lb
Cooler Line Clip-to-Engine Bolt 30 - 40 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 4564
Fluid Line/Hose: Service and Repair
Removal
1. Remove the radiator cover. 2. Remove the battery. 3. Remove the air filter assembly.
4. Remove the fluid cooler tube and the fluid cooler outlet tube from the fluid cooler.
5. Remove the hose routing bracket at the frame. 6. Remove the line routing bracket at the engine.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 4565
7. Remove the transmission cooler lines.
^ Remove the fluid cooler inlet tube.
^ Remove the fluid cooler tube.
Installation
1. Install the transmission cooler lines.
^ Install the fluid cooler tube.
^ Install the fluid cooler inlet tube.
2. Install the line routing bracket and bolt at the engine. 3. Install the hose routing bracket and bolt
at the frame. 4. Connect the fluid cooler inlet tube and the fluid cooler outlet tube. 5. Install the air
filter assembly. 6. Install the battery. 7. Fill the transmission fluid to the proper level using
Motorcraft MERCON @ V Automatic Transmission fluid XT-5-QM or equivalent meeting
MERCON (R) V specification. Inspect for leaks.
8. Install the radiator cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 4566
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications
Fluid Pan: Specifications
Transmission Fluid Pan Bolts 9 - 11 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4570
Fluid Pan: Service and Repair
Removal
1. Deactivate the air suspension 2. Disconnect the battery ground cable. 3. Raise the vehicle on a
hoist. 4. Place a drain pan under the transmission fluid pan.
5. Drain transmission fluid.
^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the
bolts.
6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket.
7. Pull down evenly and remove the transmission fluid filter, seal and filter kit.
8. Remove torque converter housing plug.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4571
9. Remove the torque converter drain plug and drain the torque converter. Rotate the crankshaft to
access the drain plug.
10. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C)
magnet. 11. Flush the fluid cooler tubes. 12. Flush the torque converter.
Installation
NOTE: A new torque converter drain plug must be used.
1. Install the torque converter drain plug.
2. Install torque converter housing plug.
CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a
small screwdriver to remove the seal. Use care not to damage the main control bore.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4572
NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
3. Replace fluid filter and seal as required.
4. Position the (B) pan magnet into the (A) transmission fluid pan.
NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not
damaged, the gasket should be reused.
5. Install the transmission fluid pan and gasket.
1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan.
6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped reactivate
the air suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4573
NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts).
10. Fill transmission to proper fluid level.
^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting
Ford specification MERCON(R) V.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications
Fluid Pump: Specifications
Front Pump Bolts 15 - 19 ft.lb
Front Pump Support Bolts 15 - 19 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Overdrive Indicator Lamp > Component Information > Description and Operation
Overdrive Indicator Lamp: Description and Operation
The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when
the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the
automatic transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Shift Indicator > Component Information > Adjustments
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the transmission range
selector lever in the OD position.
^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate
two detents counterclockwise (OD position).
3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever.
4. Center the pointer in the middle of the OD position.
^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent
to detent and compare with transmission settings.
^ Re-adjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp >
Component Information > Description and Operation
Overdrive Indicator Lamp: Description and Operation
The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when
the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the
automatic transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift
Planetary Gears: Customer Interest A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift
Article No. 01-13-7
07/09/01
^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W
AUTOMATIC TRANSMISSION
^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1
DOWNSHIFT
FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES,
EXPEDITION, EXPLORER, F-150
LINCOLN: 1999-2001 TOWN CAR
MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER
ISSUE
Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during
the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most
2-1 downshifts. This may be caused by a Planet Support Spring that is out of position.
ACTION
Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly,
the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift,
causing the "clunk" noise. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
NOTE
THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH
HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS
PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES.
1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is
originating from the transmission during the 2-1 downshift event.
NOTE
IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH
THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF
THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED.
2. Raise and support vehicle. Refer to Workshop Manual Section 100-02.
3. Check for correct torque on the following chassis & drivetrain components:
^ Driveshaft to Pinion Flange fasteners
^ Upper and Lower Control Arm fasteners (car applications)
^ Rear Leaf Spring Fasteners (truck applications)
^ Rear Shock Absorber fasteners
^ Transmission Mount and Crossmember fasteners
4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not
corrected, continue to Step 5.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4595
5. Remove the transmission from the vehicle and disassemble down to and including the Center
Support Retaining Ring. Refer to Workshop Manual section 307-01.
6. Note the position of the Planet Support Spring. Compare to the correct installation which is
illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the
transmission case. The other tang should be loaded against the Planetary Gear Support.
7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly.
If the spring is damaged, replace with part number F5AZ-7F277-AA.
8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that
will apply equal force across the spring. This will ensure the spring is installed squarely with the
tangs loading the Transmission Case on one side and the Planetary Gear Support on the other.
9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part
number F2VY-7A136-A.
10. Lower vehicle, refill fluid to correct level and verity repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4596
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4597
Operation/Description/Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7F277 07
OASIS CODES: 502000, 504000, 597997
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul
> 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift
Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear
Downshift
Article No. 01-13-7
07/09/01
^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W
AUTOMATIC TRANSMISSION
^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1
DOWNSHIFT
FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES,
EXPEDITION, EXPLORER, F-150
LINCOLN: 1999-2001 TOWN CAR
MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER
ISSUE
Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during
the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most
2-1 downshifts. This may be caused by a Planet Support Spring that is out of position.
ACTION
Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly,
the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift,
causing the "clunk" noise. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
NOTE
THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH
HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS
PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES.
1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is
originating from the transmission during the 2-1 downshift event.
NOTE
IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH
THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF
THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED.
2. Raise and support vehicle. Refer to Workshop Manual Section 100-02.
3. Check for correct torque on the following chassis & drivetrain components:
^ Driveshaft to Pinion Flange fasteners
^ Upper and Lower Control Arm fasteners (car applications)
^ Rear Leaf Spring Fasteners (truck applications)
^ Rear Shock Absorber fasteners
^ Transmission Mount and Crossmember fasteners
4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not
corrected, continue to Step 5.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul
> 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4603
5. Remove the transmission from the vehicle and disassemble down to and including the Center
Support Retaining Ring. Refer to Workshop Manual section 307-01.
6. Note the position of the Planet Support Spring. Compare to the correct installation which is
illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the
transmission case. The other tang should be loaded against the Planetary Gear Support.
7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly.
If the spring is damaged, replace with part number F5AZ-7F277-AA.
8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that
will apply equal force across the spring. This will ensure the spring is installed squarely with the
tangs loading the Transmission Case on one side and the Planetary Gear Support on the other.
9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part
number F2VY-7A136-A.
10. Lower vehicle, refill fluid to correct level and verity repair.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul
> 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4604
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul
> 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4605
Operation/Description/Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7F277 07
OASIS CODES: 502000, 504000, 597997
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Electronic Pressure Control
Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair
Electronic Pressure Control Solenoid: Service and Repair
Removal
1. Remove the manual control lever.
CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
2. Disconnect the molded lead frame from the solenoids.
1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC).
3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead
inter-connector.
3. Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Electronic Pressure Control
Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 4609
2. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector.
^ Connect the Electronic Pressure Control (EPC) solenoid.
^ Connect the Torque Converter Clutch (TCC).
^ Connect the shift solenoid SSA and SSB.
3. Install the manual control lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair
Seals and Gaskets: Service and Repair
Special Tools
Removal
1. Turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle
on a hoist. 4. Drain the transmission fluid.
NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle flange
so they may be installed in their original positions.
5. Remove the driveshaft.
^ Remove the four bolts.
6. Separate the driveshaft from the transmission. 7. Use a High-Lift Transmission Jack to support
the transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Page 4613
8. Remove the two transmission mount nuts.
9. Remove the transmission crossmember.
^ Remove the bolts.
^ Remove the transmission crossmember.
10. Lower the transmission to access the extension housing bolts.
11. Use the (A) Seal Remover and the (B) Impact Slide Hammer to remove the (c) extension
housing seal.
12. Remove the extension housing and gasket.
1. Remove the bolts and the nuts. 2. Remove the extension housing and gasket.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Page 4614
1. Install the extension housing and gasket.
1. Position the extension housing gasket and the extension housing. 2. Install the bolts and the
nuts.
2. Install the new extension housing seal.
1. Align Extension Housing Seal Replacer with the seal. 2. Install the extension housing seal.
3. Raise and position the transmission.
4. Install the transmission crossmember.
1. Position the transmission crossmember. 2. Install the bolts.
5. Remove High-Lift Transmission Jack.
6. Install the two transmission mount nuts.
NOTE: The output shaft and the drive shaft are a balanced assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Page 4615
7. Install the driveshaft.
^ Align the yellow dots and position the driveshaft on the transmission.
^ Position the driveshaft to the rear differential.
8. Install the four retaining bolts. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. If equipped reactivate the air suspension. 12. Fill the
transmission with fluid and inspect for proper operation.
^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting
Ford specification MERCON(R) V.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Page 4616
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock
Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock
Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4626
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift
Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift
Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4632
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4636
Transmission Mode Switch: Description and Operation
The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of
the transmission control selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF
will illuminate on the transmission control selector lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4637
Transmission Mode Switch: Service and Repair
TRANSMISSION MODE SWITCH
Removal
1. Remove the Transmission Control (TC) switch.
1. Remove the TC switch cover. 2. Remove the TC switch.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4641
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4642
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4643
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4644
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4648
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications
Shift Lock Actuator: Specifications
Retaining Screw ..................................................................................................................................
.................................................... 9 Nm (80 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4653
Shift Lock Actuator: Service and Repair
Removal
1. Remove the steering column.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced in the field.
3. Remove the insert plate from the shift lock actuator.
^ Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: >
02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: >
02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4662
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock
Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock
Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4668
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Specifications
Shifter A/T: Specifications
Transmission Select Lever ..................................................................................................................
...................................................... 15 Nm (11 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Specifications > Page 4672
Shifter A/T: Service and Repair
Removal
1. Remove the ignition switch lock cylinder.
2. Remove the upper steering column shroud.
3. Remove the transmission range selector lever.
1. Disconnect the electrical connector. 2. Remove and discard the selector lever pin. 3. Remove
the selector lever.
Installation
NOTE: The selector lever pin must be replaced whenever removed.
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications
Selector Shaft: Specifications
Manual Lever Shaft Nut 20 - 27 ft.lb
Manual Lever Shaft Outer Nut 23 - 25 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications > Page 4677
Selector Shaft: Service and Repair
Special Tools
Removal
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist. . 4. Drain the transmission fluid and remove the fluid pan and filter. 5.
Disconnect the digital Transmission Range (TR) sensor electrical connector.
6. Disconnect the transmission shift linkage.
7. Remove the digital TR sensor.
^ Remove the bolts.
^ Remove the digital TR sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications > Page 4678
8. Remove the manual control valve detent lever spring.
1. Remove the bolt. 2. Remove the manual control valve detent lever spring.
NOTE: Use a shop cloth to protect the transmission case surface.
9. Remove the manual lever shaft retaining pin.
10. Remove the nut and slide the manual control lever shaft out of the case.
11. Remove the parking lever actuating rod.
1. Remove the manual valve detent lever. 2. Remove the parking lever actuating rod.
CAUTION: Use care not to damage the manual control lever shaft bore. New seal may leak due to
damage to the bore.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications > Page 4679
12. Remove the manual control lever shaft seal.
Installation
1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal.
2. Install the parking lever actuating rod.
1. Install the parking lever actuating rod. 2. Install the manual valve detent lever.
3. Install the manual control lever shaft.
1. Install the manual control lever shaft. 2. Install the nut. 3. Install the manual lever shaft retaining
pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications > Page 4680
4. Install the manual valve detent lever spring.
1. Position the manual valve detent lever spring. 2. Install the bolt.
5. Install the digital TR sensor.
1. Install the digital TR sensor. 2. Loosely install the bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use the digital TR Sensor Alignment Tool to align the digital TR sensor slots. The tool is
designed to fit snug.
7. Tighten the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications > Page 4681
8. With manual lever in overdrive, connect the shift control cable. 9. Install the digital TR sensor
electrical connector.
10. Install the filter and transmission fluid pan. 11. Lower the vehicle. 12. Connect the battery
ground cable. 13. If equipped reactivate the air suspension.. 14. Fill the transmission with fluid and
inspect for proper operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector
Shaft, A/T > Component Information > Specifications > Page 4682
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications
Shift Cable: Specifications
Shift Cable Bracket 10 ft.lb
Shift Cable Nut 22 ft.lb
Transmission Shift Cable 17 - 23 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 4686
Shift Cable: Adjustments
1. Place the selector lever in the OD position.
^ Place 1.36 Kg (3 lbs.) weight on the selector lever.
2. Raise and support the vehicle.
3. Disconnect the shift cable and bracket from the manual control lever.
4. Place the manual control lever in the OD position.
5. Connect the transmission shift cable to the manual control lever, 6. Lower the vehicle. 7.
Remove the 1.36 Kg (3 lbs.) weight. 8. Carefully move the manual control lever from detent to
detent and compare with transmission settings. Verify that the vehicle will start in PARK
or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and
include Digital Transmission Range (DTR) sensor AM adjustment in NEUTRAL. ^
Re-adjust if necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 4687
Shift Cable: Service and Repair
Removal
1. Disconnect the transmission shift cable from the steering column.
1. Disconnect the transmission shift cable from the transmission selector lever arm and support. 2.
Disconnect the transmission shift cable from the steering column instrument panel bracket.
2. Disconnect the cable shift actuator cable fitting. 3. Push the rubber grommet and transmission
shift cable through the bulkhead. 4. Raise and support the vehicle.
5. Remove the shift cable and bracket from the automatic transmission.
1. Disconnect the transmission shift cable from the manual control lever. 2. Disconnect the shift
actuator cable fitting to release the transmission shift cable and disconnect the transmission shift
cable from the
transmission shift cable bracket.
6. Remove the transmission shift cable bracket from the transmission.
1. Remove the bolts. 2. Remove the bracket.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 4688
1. To install, reverse the removal procedure.
^ Adjust the shift cable.
2. Use new shift actuator cable fittings at the transmission selector lever arm and support and the
transmission shift cable bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip
Sun Gear: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip
Article No. 03-26-1
01/12/04
TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE
KIT - SERVICE TIP
FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES
1996-2001 EXPLORER 1994-2003 F SERIES
LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR
MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the
forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants
all must be replaced in combination. A mismatch of service parts may cause an internal noise or a
loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of
service pants. This new kit services all 4R70W transmissions built prior to the 2004 model.
ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service
parts.
The kit contains the following:
^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race)
(Figure 1)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4693
^ A forward clutch sun gear (7A399) (Figure 2)
^ A reverse sun gear (7A019) (Figure 3)
SERVICE TIP
To install, refer to the latest version Workshop Manual for disassembly and reassembly of the
transmission.
CAUTION
ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE
EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR
REVERSE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4694
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T
> Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip
Thrust Washer/Bearing: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service
Tip
Article No. 03-26-1
01/12/04
TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE
KIT - SERVICE TIP
FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES
1996-2001 EXPLORER 1994-2003 F SERIES
LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR
MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the
forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants
all must be replaced in combination. A mismatch of service parts may cause an internal noise or a
loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of
service pants. This new kit services all 4R70W transmissions built prior to the 2004 model.
ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service
parts.
The kit contains the following:
^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race)
(Figure 1)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T
> Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4699
^ A forward clutch sun gear (7A399) (Figure 2)
^ A reverse sun gear (7A019) (Figure 3)
SERVICE TIP
To install, refer to the latest version Workshop Manual for disassembly and reassembly of the
transmission.
CAUTION
ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE
EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR
REVERSE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T
> Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4700
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications
Torque Converter: Specifications
Torque Converter Drain Plug 21 - 22 ft.lb
Torque Converter Nuts 20 - 33 ft.lb
Stall Speed Min 2336
Max 2718
End Play New or Rebuilt 0.014 - 0.041 in
Used 0.119 - 0.123 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications > Page 4704
Torque Converter: Description and Operation
The torque converter transmits and multiplies torqued. The torque converter is a four-element
device: ^
impeller assembly
^ turbine assembly
^ reactor assembly
^ clutch and damper assembly
The standard torque converter components operate as follows: ^
Rotation of the converter housing and impeller set the fluid in motion.
^ The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain
through the input shaft.
^ The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
^ The clutch and damper assembly dampens powertrain torsional vibration and provides a direct
mechanical connection for improved efficiency.
^ Power is transmitted from the torque converter to the planetary gearsets and other components
through the input shaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis
Torque Converter: Testing and Inspection Diagnosis
Prior to torque converter replacement, all diagnostic procedures must be followed. This is to
prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic
evaluation can the decision be made to replace the torque converter. Begin with the normal
diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the
Customer's Concern. 3. Verify the Condition - Perform the Torque Converter Operation Test. 4.
Perform Diagnostic Procedures.
^ Run on-board diagnostics. ^
Repair all non-transmission related Diagnostic Trouble Codes (DTCs) first.
^ Repair all transmission DTCs.
^ Rerun on-board diagnostic to verify repair.
^ Perform Line Pressure Test.
^ Perform Stall Speed Test.
^ Perform Diagnostic Routines. ^
Use the Diagnosis by Symptom Index to locate the appropriate routine that best describes the
symptom(s). The routine will list all possible components that may cause or contribute to the
symptom. Check each component listed; diagnose and repair as required before changing the
torque converter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4707
Torque Converter: Testing and Inspection End Play Check
1. Insert End Play Checking Tool into the torque converter pump drive.
1. Position End Play Checking Tool. 2. Tighten the inner post until the tool is securely locked.
2. Attach Dial Indicator With Bracketry to End Play Checking Tool.
^ Position the dial indicator bottom on the converter pump drive hub and zero the dial.
3. Lift up on End Play Checking Tool and note the dial indicator reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4708
^ If the reading exceeds end play limits, replace the torque converter.
4. Remove the dial indicator and tool.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4709
Torque Converter: Testing and Inspection Leakage Checks
Special Tools
1. Clean the outside surface of the torque converter.
2. Install Torque Converter Leak Check Tool and Gasket into convert hub.
WARNING: Always follow proper safety procedures while using press.
3. Install the torque converter with the installed leak check tool into the Arbor press.
Secure the press. Apply enough force from the press to seal tool into the torque converter.
NOTE: Use clean dry shop air.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4710
4. Apply air pressure to valve on leak check tool.
5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap
bubble solution may be applied around those areas
to aid in diagnosis. If leaks are present, replace converter.
6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove
tool.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4711
Torque Converter: Testing and Inspection One-Way Clutch Check
Special Tools
1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer.
2. Install Converter Clutch Torquing Tool in the converter pump drive.
3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise while
holding the (C) Converter Clutch Holding Tool.
^ The converter should lock up and hold torque.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4712
^ The torque converter one-way clutch should rotate freely in the clockwise direction.
^ Try the clutch for lockup and hold in at least five positions.
^ If the torque converter fails the lockup test torque, replace the torque converter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4713
Torque Converter: Testing and Inspection
Diagnosis
Prior to torque converter replacement, all diagnostic procedures must be followed. This is to
prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic
evaluation can the decision be made to replace the torque converter. Begin with the normal
diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the
Customer's Concern. 3. Verify the Condition - Perform the Torque Converter Operation Test. 4.
Perform Diagnostic Procedures.
^ Run on-board diagnostics. ^
Repair all non-transmission related Diagnostic Trouble Codes (DTCs) first.
^ Repair all transmission DTCs.
^ Rerun on-board diagnostic to verify repair.
^ Perform Line Pressure Test.
^ Perform Stall Speed Test.
^ Perform Diagnostic Routines. ^
Use the Diagnosis by Symptom Index to locate the appropriate routine that best describes the
symptom(s). The routine will list all possible components that may cause or contribute to the
symptom. Check each component listed; diagnose and repair as required before changing the
torque converter.
End Play Check
1. Insert End Play Checking Tool into the torque converter pump drive.
1. Position End Play Checking Tool. 2. Tighten the inner post until the tool is securely locked.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4714
2. Attach Dial Indicator With Bracketry to End Play Checking Tool.
^ Position the dial indicator bottom on the converter pump drive hub and zero the dial.
3. Lift up on End Play Checking Tool and note the dial indicator reading.
^ If the reading exceeds end play limits, replace the torque converter.
4. Remove the dial indicator and tool.
Leakage Checks
Special Tools
1. Clean the outside surface of the torque converter.
2. Install Torque Converter Leak Check Tool and Gasket into convert hub.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4715
WARNING: Always follow proper safety procedures while using press.
3. Install the torque converter with the installed leak check tool into the Arbor press.
Secure the press. Apply enough force from the press to seal tool into the torque converter.
NOTE: Use clean dry shop air.
4. Apply air pressure to valve on leak check tool.
5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap
bubble solution may be applied around those areas
to aid in diagnosis. If leaks are present, replace converter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4716
6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove
tool.
One-Way Clutch Check
Special Tools
1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer.
2. Install Converter Clutch Torquing Tool in the converter pump drive.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4717
3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise while
holding the (C) Converter Clutch Holding Tool.
^ The converter should lock up and hold torque.
^ The torque converter one-way clutch should rotate freely in the clockwise direction.
^ Try the clutch for lockup and hold in at least five positions.
^ If the torque converter fails the lockup test torque, replace the torque converter.
Operation Test
1 Of 2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4718
2 Of 2
This test verifies that the torque converter clutch control system and the torque converter are
operating properly. 1. Perform Quick Test.
Check for Diagnostic Trouble Codes (DTCs).
2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by
driving the vehicle at highway speeds for approximately 15 minutes in OD position. 4. After normal
operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph)
and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped,
and decrease about five seconds after pedal is released. If this does not occur, refer to
Torque Converter Operation Concerns in the Diagnosis by Symptom Chart.
6. If the vehicle stalls in OD or manual 2 at idle with vehicle at a stop, move the transmission range
selector lever to manual 1 position. If the vehicle
stalls, refer to Torque Converter Operation Concerns in the Diagnosis by Index. Repair as required.
If the vehicle does not stall in OD, refer to Diagnosis by Symptom.
7. If the vehicle exhibits a vibration during the road test complete the Road Test Evaluation Form.
This form will aid the technician in determining
the source of the vibration.
NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque
converter clutch shudder.
a. spark plugs - check for cracks, high resistance or broken insulators b. plug wires c. fuel injector filter may be plugged d. fuel contamination - poor engine performance e. EGR valve - valve may let
in too much exhaust gas and cause engine to run lean f.
vacuum leak - engine will not get proper air/fuel mixture
g. MAP/MAF sensor - improper air/fuel mixture h. H02S sensor - too rich/lean air/fuel mixture i.
fuel pressure - may be too low
j. engine mounts -loose/damaged mounts can cause vibration concerns
k. axle joints - check for vibration
Stator to Impeller Interference Check
NOTE: Front pump support may remain in front pump support and gear during this test.
1. Position the front pump support with the splines up.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4719
2. Mount (A) torque converter on the (B) front pump support with the splines on the one-way clutch
inner race, engaging the mating splines of the
front pump support.
3. Hold the (A) front pump support stationary and rotate the (B) torque converter counterclockwise.
^ The torque converter should rotate freely with no signs of scraping.
^ If there are signs of scraping, replace the torque converter.
Stator to Turbine Interference Check
NOTE: Front pump support may remain in front pump support and gear during this test.
1. Position the torque converter with the pump drive up.
2. Install the (A) front pump support to engage the mating splines of the front pump support shaft
on the (B) torque converter. 3. Install the forward clutch cylinder and shaft engaging the splines
with the rear clutch hub.
4. Check for stator to turbine interference.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Diagnosis > Page 4720
1. Hold the front pump support stationary. 2. Attempt to rotate the forward clutch cylinder and shaft.
^ The turbine and torque converter clutch assemblies should rotate in both directions not exceeding
maximum torque of 9.5 Nm (7 ft. lbs.) without any signs of metallic interference or scraping noise.
5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the
turbine. In such cases, the torque converter must be
replaced. ^
The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause
interference when installing the torque converter into the crankshaft. Check the converter front
impeller hub for nicks or sharp edges that would damage the pump seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Service and Repair > Cleaning and Inspection
Torque Converter: Service and Repair Cleaning and Inspection
1. If the torque converter is being replaced, continue with Substep 2 of Step 2. 2. If the torque
converter is not being replaced, the following procedures must be performed:
1. The torque converter must be thoroughly cleaned.
^ Torque converters with drain plugs can be cleaned by using Torque Converter/Oil Cooler
Cleaner.
^ Torque converters without drain plugs can be cleaned by hand. Partially fill the torque converter
using only recommended transmission fluid for the applicable transmission. Hand agitate the
torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid
specified for transmission, and reinstall.
2. All cooler tubes must be thoroughly cleaned by backward and forward flushing. 3. If the cooler is
to be replaced, use only factory approved service parts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Service and Repair > Cleaning and Inspection > Page 4723
Torque Converter: Service and Repair Flushing
Special Tools
NOTE: When the transmission has been repaired for internal damage the torque converter must be
cleaned using a mechanically agitated cleaner.
1. Use Torque Converter/Oil Cooler Cleaner to clean and flush the torque converter. 2. After
flushing, drain the remainder of the solvent. 3. Add 1.9 liter (2 qt.) of clean transmission fluid to the
converter and agitate by hand. 4. Thoroughly drain the solution.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Service and Repair > Cleaning and Inspection > Page 4724
Torque Converter: Service and Repair Service and Replacement
1. The torque converter must be replaced if one or more of the following statements are true:
^ A torque converter malfunction has been determined based on complete diagnostic procedures.
^ Converter studs (S), impeller hub or bushing are damaged.
^ Discoloration (due to overheating).
^ The torque converter is found to be out of specification when performing one of the following
torque converter checks: ^
One-Way Clutch Check
^ End Play Check
^ Stator to Turbine Interference Check
^ Stator to Impeller Interference Check
^ Torque Converter Leak Check
^ Evidence of transmission assembly or fluid contamination due to the following transmission or
converter failure modes: ^
Major Metallic Failure
^ Multiple Clutches or Clutch Plate Failures
^ Sufficient Component Wear which results in Metallic Contamination
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Service and Repair > Page 4725
Torque Converter: Tools and Equipment
Special Tools
Special Tools
Special Tools
Special Tool(s)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications
Transmission Cooler: Specifications
Transmission Fluid Cooler Mounting Bolts 12 - 14 ft.lb
Cooler Clip-to-Frame Bolt 7 - 9 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Page 4732
Transmission Cooler: Description and Operation
The transmission fluid cooler is an Oil-To-Air (OTA) fluid cooler with a thermostatic bypass valve.
The fluid cooler is mounted between the radiator and the condenser. ^
When the transmission fluid is cold and the thermostatic valve is closed, the transmission fluid does
not circulate through the fluid cooler.
^ As the transmission fluid temperature increases, the thermostatic bypass valve opens and allows
the transmission fluid to circulate through the fluid cooler.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Flow of Diagnosis
Transmission Cooler: Flow of Diagnosis
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and OTA fluid cooler.
These contaminants are a major cause of recurring transmission concerns and must be removed
from the system before the transmission is but back into service. The OTA fluid cooler is not
serviceable with existing equipment due to the thermostatic bypass valve, it must be replaced.
When fluid leakage is found in the fluid cooler, replace the fluid cooler.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Flow of Diagnosis > Page 4735
Transmission Cooler: Initial Inspection and Diagnostic Overview
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and OTA fluid cooler.
These contaminants are a major cause of recurring transmission concerns and must be removed
from the system before the transmission is but back into service. The OTA fluid cooler is not
serviceable with existing equipment due to the thermostatic bypass valve, it must be replaced.
When fluid leakage is found in the fluid cooler, replace the fluid cooler.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Flow of Diagnosis > Page 4736
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Backflushing and Cleaning
Transmission Cooler: Service and Repair Backflushing and Cleaning
1. When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into
the torque converter and OTA fluid cooler. These contaminants are a major cause of recuffing
transmission concerns and must be removed from the system before the transmission is but back
into service. The OTA fluid cooler is not serviceable with existing equipment due to the thermostatic
bypass valve.
2. The OTA fluid cooler must be replaced under the following conditions:
^ major metallic failure.
^ multiple clutches or clutch plate failure.
^ sufficient component wear that results in metallic contamination.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Backflushing and Cleaning > Page 4739
Transmission Cooler: Service and Repair Removal and Installation
Removal
1. Remove the cover. 2. Remove the battery. 3. Remove the air filter assembly.
4. Disconnect the fluid cooler tube and the fluid cooler outlet tube at the transmission fluid cooler.
Plug the fluid cooler outlet tube and the fluid
cooler inlet tube to prevent contamination.
5. Disconnect the power steering cooler lines at the fluid cooler. Plug the power steering cooler
lines to prevent contamination.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Backflushing and Cleaning > Page 4740
6. Remove the upper radiator mounts.
7. Remove the bolts and remove the fluid cooler.
Installation
1. Install the fluid cooler.
^ Position the fluid cooler.
^ Install the screws.
2. Install the upper radiator mounts and bolt
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Backflushing and Cleaning > Page 4741
3. Connect the power steering lines to the fluid cooler.
4. Connect the fluid cooler inlet tube and the fluid cooler outlet tube to the fluid cooler. 5. Fill the
power steering reservoir. 6. Install the air filter assembly. 7. Install the battery. 8. Fill the
transmission fluid to the proper level using Motorcraft MERCON (R) V Automatic Transmission fluid
XT-5-QM or equivalent meeting
MERCON (R) V specification. Inspect for leaks.
9. Install the radiator cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Page 4745
Transmission Mode Switch: Description and Operation
The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of
the transmission control selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF
will illuminate on the transmission control selector lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Page 4746
Transmission Mode Switch: Service and Repair
TRANSMISSION MODE SWITCH
Removal
1. Remove the Transmission Control (TC) switch.
1. Remove the TC switch cover. 2. Remove the TC switch.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4751
Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4752
^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4753
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4754
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4755
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4756
Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4757
Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4778
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4779
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4780
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4781
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4782
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4783
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4784
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4785
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4786
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4787
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4788
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4789
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4790
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4791
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4792
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4793
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4794
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4795
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4796
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4797
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4798
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4799
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4800
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4801
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4802
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4803
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4804
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4805
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4806
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4807
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4808
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4809
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4810
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4811
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4812
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4813
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4814
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4815
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4816
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4817
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4818
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4819
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4820
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4821
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4822
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4823
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4824
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4825
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4826
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4827
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4828
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4829
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4830
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4831
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4832
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4833
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4834
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4835
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4836
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4837
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4838
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4839
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4840
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4841
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4842
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4843
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4844
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4845
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Page 4846
Transmission Mount: Specifications
Rear Transmission Support Crossmember Bolts 35 - 46 ft.lb
Transmission Mount Nuts 25 - 34 ft.lb
Transmission Mount Bolts 50 - 68 ft.lb
Rear Insulator Bolts 58 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Transmission Insulator and Retainer
Transmission Mount: Service and Repair Transmission Insulator and Retainer
Removal
1. Remove transmission support crossmember.
2. Remove the nuts from the transmission support insulator and remove the transmission support
insulator.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Transmission Insulator and Retainer > Page 4849
Transmission Mount: Service and Repair Transmission Support Crossmember
Removal
1. Deactivate the air suspension 2. Disconnect the battery ground cable. 3. Raise the vehicle on a
hoist. 4. Remove the exhaust system. 5. Support the transmission with a suitable jack.
6. Remove the transmission support crossmember.
1. Remove the nuts retaining the transmission support insulator to the transmission support
crossmember. 2. Remove the bolts retaining the transmission support crossmember to the body
brackets. Remove the transmission support crossmember.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 4853
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 4854
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 4855
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Specifications > Page 4856
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test
Port, A/T > Component Information > Specifications
Transmission Pressure Test Port: Specifications
Pressure Tap Plugs .............................................................................................................................
......................................... 8-16 Nm (71-141 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Specifications > Page 4863
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications
Valve Body: Specifications
Main Control Valve Body Bolts 80 - 97 in.lb
Main Control Valve Body Cover Plate Bolts 80 - 97 in.lb
Main Control Valve Body Separator Plate Bolts 80 - 97 in.lb
Manual Control Valve Detent Lever Spring Bolt 62-97 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 4867
Valve Body: Service and Repair
Removal
1. Disconnect battery ground cable. 2. Raise and support the vehicle. 3. Drain transmission fluid
and remove the transmission fluid pan and filter.
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
4. Disconnect the molded lead frame from the solenoids.
1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC).
3. Disconnect the electronic pressure control (EPC) solenoid0 4. Disconnect the bulkhead
inter-connector.
5. Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid.
1. Remove the bolts. 2. Remove the shift solenoid and the Torque Converter Clutch (TCC)
solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 4868
6. Remove the manual control valve detent lever spring.
1. Remove the bolt. 2. Remove the manual control valve detent lever spring.
7. Remove the 23 valve body to case bolts. 8. Remove the main control valve body and discard the
pump outlet screen.
Installation
NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the
manual valve in the proper location prior to installing the bolts.
1. Position the main control valve body gasket and main control valve body using the two alignment
bolts as a guide.
NOTE: The main control valve body bolts will be tightened in later steps.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 4869
2. Loosely install the bolts.
NOTE: The main control valve body bolts will be tightened in later steps.
3. Loosely install the bolts.
4. Install the manual control valve detent lever spring.
1. Position the manual control valve detent lever spring. 2. Install the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 4870
5. Tighten the main control valve body bolts in the sequence shown.
6. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid.
1. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 2. Install the bolts.
7. Connect the molded lead frame to the solenoids.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 4871
^ Connect the bulkhead inter-connector.
^ Connect the Electronic Pressure Control (EPC) solenoid.
^ Connect the Torque Converter Clutch (TCC).
^ Connect the shift solenoid SSA and SSB.
CAUTION: If installing a new filter, and the grommet remains in the main control bore, carefully use
a small screwdriver to remove the grommet. Use care not to damage the main control bore.
NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and
seal.
8. Replace fluid filter and seal as required.
9. Position the (B) pan magnet into the (A) transmission fluid pan.
NOTE: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket
should be reused.
10. Install the transmission fluid pan.
1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 4872
11. Install the bolts. 12. Lower the vehicle. 13. Connect the battery ground cable. 14. Fill the
transmission with fluid and check for proper operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored
Wiring Harness: Customer Interest A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored
Article No. 99-19-7
09/20/99
^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED
IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W
TRANSMISSION
^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION
- DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED
IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W
TRANSMISSION
^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP
(TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND
P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999
FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150,
F-250 LD
LINCOLN: 1999 TOWN CAR
MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER
This TSB article is being republished in its entirety to include additional vehicles and to correct the
Service Procedure.
ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp
(MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs)
may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid
interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being
fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect.
ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern
is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop
Manual. If root cause is not determined, continue with this TSB.
2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4881
3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid
connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently
remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect
(-7G276-) per the appropriate model Workshop Manual, Section 307-01.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4882
4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if
any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the
terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the
bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are
spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect
(F8AZ-7G276-AA).
5. Reassemble.
PART NUMBER
F8AZ-7G276-AA Bulkhead Interconnect
F8AZ-7G276-BA Solenoid Interconnect
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 99-18-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4883
OPERATION DESCRIPTION TIME
991907A Perform Inspection And 1.3 Hrs.
Replace Bulkhead Interconnect
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G276 42
OASIS CODES: 206000, 501000, 502000, 504000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep
> 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored
Wiring Harness: All Technical Service Bulletins A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored
Article No. 99-19-7
09/20/99
^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED
IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W
TRANSMISSION
^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION
- DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED
IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W
TRANSMISSION
^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP
(TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND
P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999
FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150,
F-250 LD
LINCOLN: 1999 TOWN CAR
MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER
This TSB article is being republished in its entirety to include additional vehicles and to correct the
Service Procedure.
ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp
(MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs)
may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid
interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being
fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect.
ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern
is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop
Manual. If root cause is not determined, continue with this TSB.
2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep
> 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4889
3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid
connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently
remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect
(-7G276-) per the appropriate model Workshop Manual, Section 307-01.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep
> 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4890
4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if
any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the
terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the
bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are
spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect
(F8AZ-7G276-AA).
5. Reassemble.
PART NUMBER
F8AZ-7G276-AA Bulkhead Interconnect
F8AZ-7G276-BA Solenoid Interconnect
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 99-18-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep
> 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4891
OPERATION DESCRIPTION TIME
991907A Perform Inspection And 1.3 Hrs.
Replace Bulkhead Interconnect
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G276 42
OASIS CODES: 206000, 501000, 502000, 504000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Specifications
Carrier Bearings: Specifications
Differential Bearing Cap Bolt ...............................................................................................................
................................................. 105 Nm (77 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Specifications
Differential Case: Specifications
Differential Case Maximum Runout
................................................................................................................................................. 0.076
mm (0.003 inch)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation
Differential Case: Service and Repair Removal and Installation
Removal
1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and visually inspect
the parts for wear or damage.
3. Rotate the differential case to see if there is any roughness which would indicate damaged
bearings or gears.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4902
4. Position the special tool and inspect ring gear backlash and ring gear backface runout.
CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps
must be installed in their identical locations and positions. Mark the bearing cap position before
removal.
5. Loosen the differential case.
1. Remove the four bearing cap bolts. 2. Remove the two bearing caps.
WARNING: Be careful not to allow the differential case to fall.
CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the
machined surface from damage.
6. Use the pry bar and the wood block to remove the differential case from the rear axle housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4903
7. Remove the 10 ring gear bolts.
CAUTION: Care should be taken not to damage the ring bolt hole threads.
8. Insert a punch in the bolt holes, and drive off the ring gear.
9. Install the differential case. Position the differential case assembly, including the bearing cups
and shims, in the rear axle housing. Install the
differential bearing caps and the differential bearing cap bolts.
10. Position the special tool.
1. Rotate the differential case to make sure the differential bearings are correctly seated. 2.
Position the special tool.
NOTE: If runout is less than the specification, install a new ring gear and pinion. If runout exceeds
specification, the ring gear is true and the concern is due to either a damaged differential case or
differential bearings. Inspect the differential bearings. If the differential bearings are not damaged,
install new both the differential case and the differential bearings.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4904
11. Measure the differential case runout without the ring gear.
1. Rotate the differential case. 2. Check and note the differential case runout.
12. Remove the differential case from the rear axle housing and remove the differential bearings
using the special tools.
13. Using the special tool install the new differential bearings on the differential case.
14. Position the differential case assembly, including the bearing cups and shims in the rear axle
housing.
^ Tighten bearing caps to specification.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4905
15. Measure the differential case runout without the ring gear.
^ Check the case runout again with the new differential bearings.
^ If the runout is now less than the specification shown, use the new differential bearings for
assembly.
^ If the runout is still excessive, the differential case is damaged and must be installed new.
Installation
CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are
aligned.
1. Press the ring gear on the differential case.
2. Install the ring gear bolts.
^ Apply Stud and Bearing Mount EOAZ- 19554-BA or equivalent meeting Ford specification
WSK-M2G349-A I to ring gear bolts.
3. With pinion depth set and pinion installed, place the differential case in the rear axle housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4906
4. Install a shim on the left side.
CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps
must be installed in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.
5. Install the left bearing cap and loosely install the bearing cap bolts.
6. Install progressively larger shims on the right side until the largest shim selected can be
assembled by hand.
7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4907
8. Rotate the differential case to make sure it rotates freely.
9. Using the special tool measure the ring gear backlash.
^If the backlash is within specification, go to Step 14. The specification shown is the full allowable
range. ^
If a zero back] ash condition occurs, go to Step 10.
^ If the backlash is not within specification, go to Step 11.
10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51
mm (0.020 inch) from the LH side to allow
backlash indication. Check the backlash. Repeat Step 9.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4908
11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a
thinner shim as shown.
^ If the backlash is not within specification, correct by increasing the thickness of one differential
bearing shim and decreasing the thickness of the other differential bearing shim by the same
amount.
12. Rotate the differential several times to make sure the differential bearings are correctly seated.
13. Using the special tool recheck the backlash.
^ If the backlash is within specification, go to Step 14. If the backlash is not within specification,
repeat Step 9.
^ The specification shown is the full allowable range.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4909
14. Remove the bearing caps and bolts.
^ To establish differential bearing preload, increase both left and right shim sizes by the
specification shown in the illustration.
^ Using the special tool, make sure the differential bearing shims are fully seated and the assembly
turns freely.
15. Install the bearing caps and bearing cap bolts.
16. Using the special tool recheck the backlash.
^ The specification shown is the full allowable range.
17. Install the axle shafts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4910
Differential Case: Service and Repair Disassembly and Assembly
Differential Case and Ring Gear-Conventional
Special Tools
Disassembly
1. Remove the differential case.
2. Remove the 10 ring gear bolts.
CAUTION: Care should be taken not to damage the bolt hole threads.
3. Insert a punch in the bolt holes and drive the ring gear off.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4911
4. Using the special tools remove the differential bearing, if required.
5. Remove the differential pinion shaft lock bolt.
6. Remove the differential pinion shaft.
7. Rotate and remove the differential pinion gears and differential pinion thrust washers.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4912
8. Remove the differential side gears and the differential pinion thrust washers.
Assembly
1. Use Thermally Stable Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C
I 97-A to lubricate the differential side gear
thrust washers and the differential side gear journals. Position the differential side gear thrust
washers on the differential side gears.
2. Position the differential side gears.
3. Use Thermally Stable Rear Axle Lubricant XY-80W90-QL meeting Ford specification
WSP-M2C197-A to lubricate the differential pinion thrust
washers and the differential pinion gears and assemble.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4913
4. Engage the differential pinion gears opposite the differential side gears.
5. Rotate the differential pinion gears to align with the differential pinion shaft bore.
6. Insert the differential pinion shaft.
^ Align the hole in the differential pinion shaft with the hole in the differential case.
NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock(R) and
Sealer EOAZ- 19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and
ESE-M4G204-A2 prior to installation.
7. Install a new differential pinion shaft lock bolt and tighten finger-tight.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4914
8. Using the special tool install the new differential bearings on the differential case.
NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make
sure the ring gear bolt holes align with the differential case bolt holes correctly.
9. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with
the slot on the differential case.
10. Press the ring gear on the differential case.
11. Install the ring gear bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4915
Apply Stud and Bearing Mount EOAZ- I 9554-BA or equivalent meeting Ford specification
WSK-M2G349-A I to ring gear bolts.
12. Install the differential case.
Differential Case and Ring Gear-Traction-LOK(R)
Disassembly
1. Remove the differential case.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4916
2. Remove the 10 ring gear bolts.
CAUTION: Care should be taken not to damage the bolt hole threads.
3. Insert a punch in the bolt holes and drive the ring gear off.
4. Using the special tools remove the differential bearing.
^ Repeat for the other side.
5. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
WARNING: Due to the spring tension, care must be used when removing the differential clutch
spring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4917
6. Remove the differential clutch spring.
7. Remove the differential gears.
1. Remove the two differential pinion gears. 2. Remove the two differential side gears. 3. Remove
the two differential pinion thrust washers.
CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled
in the same sequence.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4918
8. Remove the differential clutch packs and differential side gears and tag them "right" and "left"
with the shim.
^ Clean and inspect the remaining parts of the differential case for wear or damage and install new
parts as necessary.
CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe
components with a clean, lint-free cloth only.
9. Clean and inspect the differential clutch packs for wear and install new parts as necessary.
Assembly
CAUTION: 118 ml. ( 4. oz) of the specified Ford Friction Modifier must be used in the axle.
1. Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier
C8AZ- 1913546-A or equivalent meeting Ford
specification EST-M2C I 18-A for at least 15 minutes.
CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4919
2. Assemble the differential clutch packs (without the shims) on the respective differential side
gears.
CAUTION: Make sure the correct mandrel is used with the special tool.
3. Place the base portion of the special tool in a vise. Install the differential clutch pack and
differential side gear (without the shim) on the gauge.
4. Position the special tool hand-tight on top of the differential clutch pack.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4920
5. Install the special tool over the disc and differential clutch pack.
6. Install the nut of the gauge over the top and base stud.
7. Use a Feeler Gauge and select the thickest blade that will enter between the tool and the
differential clutch pack. The reading will be the thickness
of the new clutch shim.
8. Remove the special tool from the clutch pack and side gear assembly. 9. Install the shim(s) on
the clutch pack and side gear assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4921
10. Install the differential side gear in the differential case.
11. Install the differential pinion gears with differential pinion thrust washers in the differential case.
12. Install the differential clutch spring, using a soft-faced hammer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4922
13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
14. Using the special tool install the differential bearing on the differential case.
^ Repeat for the other side.
15. Check the torque required to rotate one differential side gear.
^ Mount the differential case and special tool in a vise.
^ The initial minimum break-away torque, if original clutch plates are used, must be within
specification. The minimum rotating torque required to keep the differential side gear turning with
new clutch plates may vary.
NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make
sure the ring gear bolt holes align with the differential case bolt holes correctly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Removal and Installation > Page 4923
16. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with
the slot on the differential case.
17. Press the ring gear on the differential case.
18. Install the ring gear bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-Al to the ring gear bolts.
19. Install the differential case.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications
Differential Cover: Specifications
Torque Specifications
Differential housing cover bolts
...........................................................................................................................................................
45 Nm (33 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications > Page 4927
Differential Cover: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the RH kick panel area. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
1. Raise and support the vehicle.
NOTE: Empty the lubricant into a clean container for reuse.
2. Remove the differential housing cover.
1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle
housing. 2. Remove the differential housing cover.
Installation
CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential
housing cover are clean and free of oil before installing the new silicone sealant. The inside of the
rear axle must be covered when cleaning the machined surface to prevent contamination.
1. Clean the gasket mating surface of the rear axle and the differential housing cover.
2. Apply a new continuous bead of sealant to the differential housing cover.
^ Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A
and ESE-M4G 195-A.
NOTE: The differential housing cover must be installed within 15 minutes of application of the
silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to
make sure the silicone sealant has properly cured.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications > Page 4928
3. Install the differential housing cover.
1. Install the differential housing cover. 2. Install the 10 differential housing cover bolts.
CAUTION: For Traction-Lok(R) axles, first fill the rear axle with 118 ml. (4 oz.) of specified Ford
Friction Modifier.
NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to
the level shown in the illustration.
4. Fill the rear axle with 1.8 liters (3.75 pints) of Thermally Stable Rear Axle Lubricant
XY-80W90-QL or equivalent meeting Ford specification
WSP-M2CI 97-A and install the filler plug.
5. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair
Differential Axle Housing: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the RH kick panel area. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
Raise and support the vehicle.
2. Mark the driveshaft flange and the pinion flange for correct alignment during installation.
3. Remove the four driveshaft retainer bolts and disconnect the driveshaft. 4. Remove the wheels
and tires. 5. Remove the rear disc brake calipers from the brake adapters and brake discs, and
wire the caliper out of the way. 6. Remove the rear brake discs.
7. Remove the parking brake rear cable and conduit from the parking brake cable equalizer.
^ Reroute the parking brake rear cable and conduit out of the way.
^ Repeat for the other side.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 4932
8. Remove the anti-lock brake sensors.
^ Reroute the anti-lock brake sensor wiring.
9. Remove the rear stabilizer bar from the rear stabilizer bar link and bushing.
10. Disconnect the rear stabilizer bar bracket bolts, the rear stabilizer bar brackets and the rear
stabilizer bar.
11. If equipped with rear air springs, remove the height sensor.
CAUTION: Take care not to damage the threads on the bellcrank stud. Separate the Watts linkage
from the rear axle housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 4933
12. Remove the retainer nut from the bellcrank stud.
WARNING: Use additional support straps to secure the rear axle to the jack.
13. Support the rear axle housing with a suitable jack.
14. Remove the shock absorber lower retainer nuts and remove the shock absorbers from the
retainer brackets.
15. Remove the lower control arm retainer nut and bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 4934
16. Remove the upper control arm retainer nut and bolt.
17. Unseat the air springs and lower the rear axle from the vehicle.
Installation
WARNING: Use additional support straps to secure the rear axle to the high-lift transmissions jack.
1. Raise the rear axle into position using a high-lift transmission jack.
^ Seat the air springs.
2. Install the upper control arm retainer nut and bolt and tighten.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 4935
3. Install the lower control arm retainer nut and bolt and tighten.
4. Install the shock absorbers.
^ Position the shock absorbers into the retainer brackets, and tighten the retainer nuts and bolts.
5. Remove the high-lift transmission jack.
6. Install the Watts linkage on the rear axle housing.
^ Install the retainer nut on the bellcrank stud and tighten.
7. If equipped with rear air springs, install the height sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 4936
8. Install the rear stabilizer bar retainer bolts and tighten.
9. Install the rear stabilizer bar link and bushing retainer nuts and tighten.
10. Install the anti-lock brake sensors. 11. Install the parking brake rear cable and conduit into the
parking brake cable equalizer. 12. Install the rear brake discs. 13. Install the rear disc brake
calipers on the brake discs/brake adapters.
14. Install the wheels and tires.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Page 4937
15. Position the rear driveshaft and align the marks on the pinion flange.
16. Install the four driveshaft retainer bolts. 17. If equipped with rear air springs, turn on the air
suspension switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component
Information > Specifications
Fill Plug: Specifications
Oil Filler Plug .......................................................................................................................................
.................................................... 30 Nm (22 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Capacity
Standard Axle ......................................................................................................................................
.................................................................... 1.8 - 1.9L
Traction-Lok Axle .................................................................................................................................
................................................................. 2.2 - 2.4L
Traction-Lok differentials add 4 oz of friction modifier C8AZ-19B956-A on refill.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 4945
Fluid - Differential: Fluid Type Specifications
Standard Applications
Premium Rear Axle Lubricant SAE 80W90 Specification ....................................................................
........................................................................................................................... WSP-M2C197-A
Police, Taxi, Limo Applications
High Performance Rear Axle Lubricant SAE 75W140 Specification ...................................................
............................................................................................................................................
WSL-M2C192-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Page 4946
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Specifications
Pinion Bearing: Specifications
Pinion bearing preload (used pinion bearings) 8 - 14 in.lb
Pinion bearing preload (new pinion bearings) 16 - 29 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair
Pinion Flange: Service and Repair
Special Tools
Removal
NOTE: The rear wheels and rear brake discs must be removed to prevent brake drag during drive
pinion bearing preload adjustment.
1. Remove the rear brake discs.
2. Mark the driveshaft flange and pinion flange for correct alignment during installation.
3. Remove the four driveshaft bolts and disconnect the driveshaft.
^ Position the driveshaft out of the way.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4953
4. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque required to
maintain rotation of the drive pinion gear through
several revolutions.
CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation.
5. Use Companion Flange Holding Tool to hold the pinion flange while removing the pinion nut.
6. Mark the driveshaft pinion flange in relation to the drive pinion stem to make sure of correct
alignment during installation.
7. Use a 2-Jaw Puller for Differential Case Bearings to remove the pinion flange.
Installation
1. Lubricate the pinion flange splines.
^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A.
NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4954
2. Align the pinion flange with the drive pinion shaft.
3. With the drive pinion in place in the rear axle housing, install the pinion flange using the
Companion Flange Replacer.
4. Position the new pinion nut.
CAUTION: Under no circumstances k the pinion nut to be backed off to reduce preload. If reduced
preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.
5. Use Companion Flange Holding Tool to hold the pinion flange while tightening the pinion nut.
^ Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings
are seating property. Take frequent cone and roller bearing torque preload readings until the
original recorded preload reading is obtained by rotating the pinion with a Nm (inch-pound) torque
wrench.
^ If the original recorded preload is lower than specifications, tighten to the specification for used
bearings. If the preload is higher than specification, tighten the nut to the original, trial reading as
recorded.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4955
6. Position the rear driveshaft and align the mark on the pinion flange.
7. Install the four rear driveshaft to pinion flange bolts. 8. Install the rear brake discs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 4956
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair
Pinion Gear: Service and Repair
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4960
Special Tools
Special Tools
Special Tools
Removal
1. Remove the differential case.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4961
2. Mark the driveshaft flange and the pinion flange for correct alignment during installation.
3. Remove the four driveshaft bolts and disconnect the driveshaft.
4. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque required to
maintain rotation of the pinion through several
revolutions.
5. Remove the pinion flange and pinion nut.
6. Install the special tool and, with a soft-faced hammer, drive the pinion assembly out of the front
bearing cone and remove it through the rear of the
housing. ^
Remove the rear axle drive pinion seal.
^ Remove the rear axle drive pinion shaft oil slinger.
NOTE: Remove the drive pinion collapsible spacer and discard it.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4962
7. Using the special tool remove the pinion bearing.
NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are
damaged.
8. Remove the outer differential bearing cup with the special tools.
9. Remove the inner differential bearing cup with the special tools.
Installation
1. Position the special tools and the inner and outer bearing cups in their respective bores.
1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner
pinion bearing cup. 2. Place the special tool on the outer pinion bearing cup. 3. Install the special
tool into the replacer tools.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4963
2. Tighten the Threaded Drawbar to seat the pinion bearing cups into their bores.
3. Drive the outer pinion bearing cup into the axle housing using the special tools.
4. Drive the inner pinion bearing cup into the axle housing using the special tools.
CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced.
NOTE: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point
around the cup, the cup is not correctly seated.
5. Make sure the cups are correctly seated in their bores.
NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4964
6. Assemble and position the Pinion Depth Gauge.
NOTE: This step duplicates final pinion bearing preload.
7. Tighten the special tool to the specification shown.
NOTE: The special tool must be offset to obtain an accurate reading.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4965
8. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings
and position the special tool.
9. Install the special tool.
1. Position the special tool. 2. Install the differential side bearing caps. 3. Install the four differential
side bearing cap bolts.
NOTE: ^
Drive pinion bearing adjustment shims must be flat and clean.
^ A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim
between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim
thicker than required, which results in a deep tooth contact in final assembly of integral rear axle
assemblies.
10. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ After the correct shim thickness has been determined, remove the special tools.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4966
11. Using a press and the special tool press the pinion bearing and pinion shim until they are firmly
seated on the pinion.
12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder
13. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear
bearing cone and roller, and drive pinion collapsible
spacer) into the rear axle carrier bore.
CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive
pinion becomes cocked during installation, remove it and install a new one.
14. Install a new rear axle drive pinion seal.
1. Install the front pinion bearing cone and roller. 2. Install the rear axle drive pinion shaft oil slinger
in the rear axle housing. 3. Install the rear axle drive pinion seal on the Pinion Seal Replacer.
NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG- I -C or
equivalent meeting Ford specification ESA-MIC75-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4967
15. Place the Pinion Seal Replacer in the rear axle drive pinion seal bore, and drive the rear axle
drive pinion seal into place. 16. Lubricate the pinion flange splines.
^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C I 97-A.
NOTE: Disregard the scribe marks if a new pinion flange is being installed.
17. Align the pinion flange with the drive pinion shaft.
18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special
tool.
19. Position the new pinion nut.
CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced
preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4968
20. Use the special tool to hold the pinion flange while tightening the pinion nut. 21. Install the
differential case in the rear axle housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4969
Pinion Gear: Tools and Equipment
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Page 4970
Special Tools
Special Tools
Special Tools
Special Tool(s)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Specifications
Ring Gear: Specifications
General Specifications
Maximum back face ring gear runout
........................................................................................................................................... 0.102 mm
(0.004 inch) Backlash between ring gear and pinion teeth
.......................................................................................... 0.203-0.381 mm (0.305-0.381 mm
preferred) .............................................................................................................................................
................... 0.008-0.015 inch (0.012-0.015 inch preferred) Ring gear maximum backlash variation
between teeth ................................................................................................................. 0.102 mm
(0.004 inch) Ring gear bolts ................................................................................................................
................................................................... 105 Nm (77 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair
Seals and Gaskets: Service and Repair
Special Tools
Removal
1. Remove the pinion flange.
2. Using a screwdriver, force the metal flange of the rear axle drive pinion seal up and strike with a
hammer. Install gripping pliers and remove.
Installation
1. Lubricate the new rear axle drive pinion seal.
^ Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MIC75-B.
CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
rear axle drive pinion seal and install a new seal.
2. Using the special tool install the rear axle drive pinion seal.
3. Install the pinion flange.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Page 4977
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair
Axle Bearing: Service and Repair
Special Tools
Special Tools
Removal
1. Remove the axle shaft.
CAUTION: Never remove the inner wheel bearing oil seal by itself Always remove the inner wheel
bearing oil seal and the rear wheel bearing at the same time.
NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with
foreign material.
2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear wheel bearing
and inner wheel bearing oil seal.
Installation
1. Lubricate the new rear wheel bearing.
^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C I 97-A.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Page 4982
2. Use Axle Tube Bearing Replacer to install the rear wheel bearing.
3. Lubricate the lip of the new inner wheel bearing oil seal.
^ Use Premium Long-Life Grease XG- I -C or equivalent meeting Ford specification ESA-MIC75-B.
4. Use Axle Tube/Seal Replacer to install the inner wheel bearing oil seal. 5. Install the axle shafts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Page 4983
Axle Bearing: Tools and Equipment
Special Tools
Special Tools
Special Tool(s)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair
Axle Shaft: Service and Repair
Removal
CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the rear
wheel bearings.
1. Loosen the lug nuts.
1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts.
WARNING: When equipped with rear air springs, the electrical power to the air suspension system
must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be
accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to
do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of
the vehicle during these operations.
2. Raise and support the vehicle.
3. Remove the wheel and tire assembly.
1. Remove the lug nuts. 2. Remove the wheel and tire assembly.
^
4. Remove the differential housing cover.
1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle
housing. 2. Remove the differential housing cover.
5. Remove the rear brake anti-lock sensor. 6. Remove the brake discs.
CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an
axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in
chipped or damaged components.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4988
7. Remove the differential pinion shaft.
1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft.
CAUTION: Do not damage the rubber O-rings in the U-washer grooves.
8. Remove the U-washers.
1. Push the axle shafts inboard. 2. Remove the U-washers.
9. Reinstall the differential pinion shaft.
1. Install the differential pinion shaft. 2. Install the differential pinion shaft lock bolt finger-tight.
CAUTION: Do not damage the inner wheel bearing oil seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4989
10. Remove the two axle shafts.
Installation
1. Lubricate the lip of the inner wheel bearing oil seal.
^ Use Premium Long-Life Grease XG- I -C or equivalent meeting Ford specification ESA-MIC75-B.
CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an
axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in
chipped or damaged components.
2. Remove the differential pinion shaft.
1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft.
CAUTION: Do not damage the inner* r wheel bearing oil seal.
3. Install the two axle shafts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 4990
CAUTION: Do not damage the rubber
O-rings in the U-washer grooves.
4. Install the U-washers.
1. Position the two U-washers on the button end of the axle shaft. 2. Pull the axle shafts outward to
seat the U-washers in the side gears.
5. Install the differential pinion shaft.
1. Align the hole in the differential pinion shaft with the lock bolt hole. 2. Install the differential pinion
shaft lock bolt.
6. Install the brake discs. 7. Install the rear brake anti-lock sensor. 8. Install the differential housing
cover and fill the rear axle housing with 1.8 liters (3.75. pints) of Thermally Stable Rear Axle
Lubricant
XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A.
WARNING: Always remove any corrosion, dirt or foreign material that may be present on the
mounting surfaces of the wheel or the surface of the wheel hub or rear brake disc that contacts the
wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can
cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of
control.
9. Clean the wheel hub and mounting surfaces.
NOTE: If equipped with air suspension, reactivate the system by turning the air suspension switch
on.
10. Install the tire and wheel assembly.
1. Position the tire and wheel assembly. 2. Install the lug nuts and lower the vehicle. 3. Tighten the
lug nuts. 4. Install the center cap.
^
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4995
Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4996
^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4997
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4998
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4999
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5000
Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5001
Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5002
The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5003
g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5004
engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5008
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5036
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5037
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5038
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5039
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5040
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5041
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5042
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5043
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5044
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5045
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5046
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5047
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5048
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5049
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5050
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5051
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5052
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5053
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5054
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5055
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5056
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5057
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5058
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5059
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5060
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5061
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5062
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5063
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5064
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5065
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5066
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5067
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5068
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5069
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5070
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5071
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5072
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5073
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5074
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5075
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5076
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5077
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5078
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5079
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5080
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5081
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5082
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5083
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5084
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5085
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5086
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5087
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5088
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5089
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 5090
Wheel Bearing: Service Precautions
CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the
improper grease can cause bearing damage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 5091
Wheel Bearing: Testing and Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new
wheel hub.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 5092
Wheel Bearing: Service and Repair
FRONT WHEEL HUB
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. Remove and discard the front hub cap grease seal.
5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it
can back off resulting in loss of the front
wheel and or damage to the wheel hub and bearing assembly.
Remove the front axle wheel hub retainer. Discard the retainer.
6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS
sensor lead or the ABS sensor ring.
NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to
remove.
Remove the wheel hub and bearing assembly.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 5093
1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the
ABS sensor lead or the ABS sensor ring.
Install the wheel hub and bearing assembly.
2. Install a new front axle wheel hub retainer.
3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire
assembly. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Front Axle Wheel Hub Retainer
...........................................................................................................................................................
300 Nm (221 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W
Vibration/Fluid Leak At Extension Housing
Drive/Propeller Shaft: Customer Interest A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W
Vibration/Fluid Leak At Extension Housing > Page 5107
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-1 > Sep > 99 > A/T - 4R70W
Vibration/Fluid Leak At Extension Housing > Page 5108
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis
Drive/Propeller Shaft: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5114
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5115
For Dealerships without An Electronic Vibration Analyzer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5116
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5117
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5118
Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Drive/Propeller Shaft: All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak At
Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 5123
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
99-18-1 > Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 5124
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis
Drive/Propeller Shaft: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5130
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5131
For Dealerships without An Electronic Vibration Analyzer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5132
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5133
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
01-1-14 > Jan > 01 > Suspension/Driveline - Vibration Diagnosis > Page 5134
Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Page 5135
Drive/Propeller Shaft: Specifications
Drive shaft- to-drive shaft pinion flange bolts 70 - 95 ft.lb
Driveshaft bolts 83 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Page 5136
Drive/Propeller Shaft: Description and Operation
All driveshaft assemblies are balanced. If the vehicle is to be undercoated, cover the driveshaft
assembly to prevent overspray of any undercoating material. The driveshaft has the following
features: ^
A tubular shaft used to transfer torque from the engine, through the transmission to the ring and
pinion in the rear axle, which transmits the torque to the wheels.
^ Consists of two single cardan universal joints, a driveshaft slip-yoke and a driveshaft centering
socket yoke.
^ The splined slip-yoke permits the driveshaft to move forward and rearward on the transmission
output shaft during drivetrain movement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Page 5137
Drive/Propeller Shaft: Service and Repair
Removal
1. Raise and support the vehicle.
2. Index-mark the driveshaft.
^ Place a paint index-mark on the pinion flange to the driveshaft centering socket yoke.
3. Remove the driveshaft-to-driveshaft pinion flange bolts. 4. Lower the driveshaft and slide the
driveshaft rearward from the transmission output shaft.
^ Place a paint index-mark on the driveshaft slip-yoke to the transmission output shaft.
^ Plug the extension housing to prevent fluid loss.
Installation
NOTE: ^
Inspect the extension housing seal for damage, install new as necessary.
^ Lubricate the slip-yoke spline with Premium Long-Life Grease XG- I -C or -K or equivalent
meeting Ford specification ESA-M I C75-13.
^ Install the driveshaft so that the index-marks made on the transmission output shaft to the
driveshaft slip-yoke and the index-marks made on the pinion flange to the driveshaft centering
socket yoke are aligned.
^ If installing a new driveshaft, align the factory-made yellow paint mark at the rear of the driveshaft
tube with the factory-made yellow paint mark on the pinion flange. If the paint marks are not visible.
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation
Universal Joint: Description and Operation
Universal joints have the following: ^
A lubed-for-life design.
^ Nylon thrust washers, located at each base of the bearing cup, which control end play, position
the needle bearings and improve grease movement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 5141
Universal Joint: Service and Repair
Special Tools
Disassembly
CAUTION: Do not clamp the driveshaft in the jaws of a vice or a similar holding fixture.
1. Place the driveshaft on a suitable workbench.
NOTE: Mark the positions of the driveshaft components relative to the driveshaft tube. This
ensures all components are reassembled in the same relationship to maintain correct balance.
2. Index the driveshaft and driveshaft components.
3. Clamp the U-Joint Tool in a vise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 5142
4. Remove the snap rings.
NOTE: If the bearing cup cannot be pressed all the way out, remove it with vise grips.
5. Remove the driveshaft slip-yoke.
1. Position the driveshaft in the U-Joint Tool. 2. Press out a bearing cup. 3. Rotate the driveshaft
180 degrees.
4. Press on the spider to remove the bearing cup from the opposite side. 5. Remove the driveshaft
slip-yoke.
6. Remove the remaining bearing cups and the spider.
7. Remove the snap rings from the driveshaft centering socket yoke end.
NOTE: If the bearing cup cannot be pressed all the way out, remove it with vise grips.
8. Remove the driveshaft centering socket yoke.
1. Position the driveshaft in the U-Joint Tool. 2. Press out a bearing cup.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 5143
3. Rotate the driveshaft 180 degrees. 4. Press on the spider to remove the bearing cup from the
opposite side.
5. Remove the driveshaft centering socket yoke.
9. Remove the remaining bearing cups and the spider.
10. Clean the driveshaft yoke area at each end of the driveshaft.
^ Inspect the driveshaft and driveshaft components for wear or damage.
Assembly
NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not use
components from other universal joints.
1. Install a new bearing cup.
1. Start a new bearing cup into the driveshaft yoke. 2. Position a new spider in the driveshaft yoke.
3. Install the driveshaft into the U-Joint Tool. 4. Press the bearing cup below the yoke surface.
NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing
the yellow snap rings, install the black snap rings also supplied in the kit.
2. Remove the driveshaft from the U-Joint Tool and install the snap ring. 3. Repeat Steps 1 and 2
for the opposite side.
4. Install a new bearing cup.
1. Start a new bearing cup into the driveshaft centering socket yoke. 2. Install the driveshaft into the
U-Joint Tool. 3. Press the bearing cup below the yoke surface.
NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing
the yellow snap rings, install the black snap rings also supplied in the kit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 5144
5. Remove the driveshaft from the U-Joint Tool and install the snap ring.
6. Repeat Steps 4 and 5 for the opposite side.
NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer.
7. Check the universal joint for freedom of movement.
8. Install a new bearing cup.
1. Start a new bearing cup into the driveshaft yoke. 2. Position a new spider in the driveshaft yoke.
3. Install the driveshaft into the U-Joint Tool. 4. Press the bearing cup 6.3 mm (0.25 inch) below the
yoke surface.
NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing
the yellow snap rings, install the black snap rings also supplied in the kit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 5145
9. Remove the driveshaft from the U-Joint Tool and install the snap ring.
10. Repeat Steps 8 and 9 for the opposite side.
11. Install a new bearing cup.
1. Start a new bearing cup into the driveshaft slip-yoke. 2. Install the driveshaft into the U-Joint
Tool. 3. Press the bearing cup 6.3 mm (0.25 inch) below the yoke surface.
NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing
the yellow snap rings, install the black snap rings also supplied in the kit.
12. Remove the driveshaft from the U-Joint Tool and install the snap ring. 13. Repeat Steps 11 and
12 for the opposite side.
NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer to seat
the bearing cups.
14. Check the universal joint for freedom of movement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 5146
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flywheel Bolts 54-64 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5150
Flex Plate: Service and Repair
Removal
1. Remove the transmission.
2. Remove the bolts.
Installation
1. Position the flywheel and loosely install the bolts. Tighten the bolts in the sequence shown.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation
Overdrive Indicator Lamp: Description and Operation
The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when
the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the
automatic transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Shift Indicator > Component Information > Adjustments
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the transmission range
selector lever in the OD position.
^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate
two detents counterclockwise (OD position).
3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever.
4. Center the pointer in the middle of the OD position.
^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent
to detent and compare with transmission settings.
^ Re-adjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5233
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5234
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5235
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5236
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5237
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5238
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5239
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5240
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5241
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5242
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5243
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5244
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5245
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5246
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5247
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5248
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5249
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5250
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5251
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5252
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5253
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5254
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5255
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5256
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5257
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5258
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for
Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for
Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5269
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5275
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5279
Transmission Mode Switch: Description and Operation
The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of
the transmission control selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF
will illuminate on the transmission control selector lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5280
Transmission Mode Switch: Service and Repair
TRANSMISSION MODE SWITCH
Removal
1. Remove the Transmission Control (TC) switch.
1. Remove the TC switch cover. 2. Remove the TC switch.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5284
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5285
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5286
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5287
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5291
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure
Regulating Solenoid, A/T] > Component Information > Service and Repair
Electronic Pressure Control Solenoid: Service and Repair
Removal
1. Remove the manual control lever.
CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
2. Disconnect the molded lead frame from the solenoids.
1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the Torque Converter Clutch (TCC).
3. Disconnect the Electronic Pressure Control (EPC) solenoid. 4. Disconnect the bulkhead
inter-connector.
3. Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure
Regulating Solenoid, A/T] > Component Information > Service and Repair > Page 5298
2. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector.
^ Connect the Electronic Pressure Control (EPC) solenoid.
^ Connect the Torque Converter Clutch (TCC).
^ Connect the shift solenoid SSA and SSB.
3. Install the manual control lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] >
Component Information > Specifications
Shift Lock Actuator: Specifications
Retaining Screw ..................................................................................................................................
.................................................... 9 Nm (80 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] >
Component Information > Specifications > Page 5302
Shift Lock Actuator: Service and Repair
Removal
1. Remove the steering column.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced in the field.
3. Remove the insert plate from the shift lock actuator.
^ Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Description and Operation
Overdrive Indicator Lamp: Description and Operation
The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when
the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the
automatic transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the transmission range
selector lever in the OD position.
^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate
two detents counterclockwise (OD position).
3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever.
4. Center the pointer in the middle of the OD position.
^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent
to detent and compare with transmission settings.
^ Re-adjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock Inoperative > Page 5324
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock
- Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock
- Inoperative > Page 5330
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5334
Transmission Mode Switch: Description and Operation
The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of
the transmission control selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF
will illuminate on the transmission control selector lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5335
Transmission Mode Switch: Service and Repair
TRANSMISSION MODE SWITCH
Removal
1. Remove the Transmission Control (TC) switch.
1. Remove the TC switch cover. 2. Remove the TC switch.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications
Transmission Position Switch/Sensor: Specifications
Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 5339
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 5340
Transmission Position Switch/Sensor: Service and Repair
Special Tools
1. If equipped turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise
the vehicle on a hoist.
4. Disconnect the manual lever shift control cable.
5. Loosen the digital Transmission Range (TR) bolts.
NOTE: Manual shift lever shaft must be in the neutral position.
6. Use digital TR sensor alignment tool, to align the digital TR sensor slots. The tool is designed to
fit snugly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 5341
7. Tighten the bolts.
8. With the manual lever in overdrive connect the shift lever control cable. 9. Install the digital TR
sensor electrical connector.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. If equipped reactivate the air
suspension..
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Specifications > Page 5342
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Output Shaft Speed (OSS) Sensor Bolt 71 - 141 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications > Page 5346
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Description and Operation
ABS Light: Description and Operation
The anti-lock brake warning indicator illuminates when the anti-lock brake control module detects a
fault in the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Description and Operation > Page 5352
ABS Light: Testing and Inspection
For testing procedures for this component, refer to Instrument Panel, Gauges and Warning
Indicators, Instrument Cluster, Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake
Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications
Anti-Lock Brake Control Module: Specifications
Retaining Screws .................................................................................................................................
................................................................. 1.8-2.8 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake
Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5356
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake
Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5357
Anti-Lock Brake Control Module: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Disconnect the anti-lock brake control module electrical connectors.
- Disconnect the control module electrical connector.
- Disconnect the pump motor electrical connector.
3. Remove the anti-lock brake control module.
1 Remove the screws.
2 Remove the module.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Mounting Bolts .....................................................................................................................................
......................................... 15-17 Nm (11-12 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 5361
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 5362
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Removal
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contract with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Disconnect the battery ground cable.
2. NOTE: Plug each port of the Hydraulic Control Unit (HCU) to prevent brake fluid from spilling.
Disconnect the brake lines.
3. Disconnect the anti-lock brake control module electrical connectors.
4. Remove the mounting bracket to HCU bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 5363
5. Remove the anti-lock brake control module.
1 Remove the screws.
2 Remove the module.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
NOTE: Bleed brake system as necessary.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Indicator Lamp > Component Information > Description and Operation
Traction Control Indicator Lamp: Description and Operation
The traction control indicator is located in the indicator lamp module and illuminates when the
traction control system is disabled.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Measured using Rotunda EEC-IV 60-Pin Breakout Box
Front and Rear 800-1400 ohms
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications > Page 5371
Wheel Speed Sensor: Mechanical Specifications
Retaining Bolts Front 36-53 in.lb
Rear 14-19 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front
Wheel Speed Sensor: Service and Repair Front
Removal
1. Disconnect the front anti-lock brake sensor electrical connector. 2. Raise and support the
vehicle.
3. Remove the routing clips.
4. Remove the front anti-lock brake sensor.
1 Remove the bolt.
2 Remove the sensor.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 5374
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 5375
Wheel Speed Sensor: Service and Repair Rear
Removal
1. Remove rear seat bottom.
2. Disconnect the rear anti-lock brake sensor electrical connector.
3. Push the sensor harness grommet through the passenger compartment floor. 4. Raise and
support the vehicle.
5. Disconnect the routing clips.
6. Remove the rear anti-lock brake sensor.
1 Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front > Page 5376
2 Remove the sensor.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure
Brake Bleeding: Service and Repair Caliper Bleeding Procedure
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the Brake Pedal (BP) and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5381
Brake Bleeding: Service and Repair Manual Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of a
new part, 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. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash
and follow the NGS instructions.
2. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the
tube in a container partially filled with clean brake fluid.
4. Have an assistant hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw
until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal,
tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5382
6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw.
8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder
screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
9. Have an assistant hold firm pressure on the brake pedal.
10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out.
While the assistant maintains pressure on the brake
pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
11. Tighten the RH front disc brake caliper bleeder screw. 12. Repeat Steps 8, 9, 10 and 11 for the
LH front disc brake caliper bleeder screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5383
Brake Bleeding: Service and Repair Master Cylinder Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can enter the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be
bled manually or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been replaced or the system has been emptied, or
partially emptied, it should be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines.
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill
the brake master cylinder reservoir with High
Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A.
4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid
flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at
the bench, install it in the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5384
6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the
brake master cylinder as follows:
1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
2 Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
3 Repeat this operation until clear, bubble-free fluid comes out.
4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5385
Brake Bleeding: Service and Repair Pressure Bleeding
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending
with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5386
Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS)
NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS)
Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened.
NOTE: Ford provides no information or procedures to bleed the brake system without the Rotunda
New Generation Star (NGS) tester/scan tool.
1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of
brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Caliper Bleeding Procedure > Page 5387
4. Tighten the RH rear bleeder screw, and disconnect the waste line.
5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder
screw, and the LH front disc brake caliper bleeder
screw, in that order.
6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the
dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps
1 through 5.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Brake Pedal Bracket Nuts
..............................................................................................................................................................
21-29 Nm (16-21 ft. lbs.) Brake Pedal Bracket Bolt .............................................................................
.................................................................................. 18-27 Nm (13-20 ft. lbs.) Pivot Shaft Nut ..........
..............................................................................................................................................................
....... 14-27 Nm (10-20 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 5391
Brake Pedal Assy: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the instrument close-out panel pushpins and remove the panel.
3. Remove the stoplight switch retaining pin.
4. Slide the stoplight switch and booster push rod from the brake pedal pin.
5. Remove the brake pedal bracket retaining bolt. 6. Remove the speed control deactivator switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 5392
7. Remove the brake pedal bracket retaining nuts. 8. Remove the brake pedal and bracket.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description
and Operation
Brake Warning Indicator: Description and Operation
The brake system warning indicator has a dual function. It illuminates when the parking brake is
applied or when a low brake fluid condition exists in the brake master cylinder reservoir. The brake
system warning indicator will illuminate when there is a pressure differential between the front and
rear brake hydraulic systems.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Front
Brake Caliper: Specifications Front
Torque Specifications:
Disc Brake Caliper Bolt
..........................................................................................................................................................
28-36 Nm (21-26 lb.ft.) Front Brake Hose Bolt ....................................................................................
.................................................................................. 48 Nm (35 lb.ft.) Front Disc Brake Caliper
Anchor Plate Bolt .................................................................................................................. 170-230
Nm (125-169 lb.ft.) Disc Brake Caliper Bleeder Screw
......................................................................................................................................... 17-24 Nm
(13-17 lb.ft.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Front > Page 5401
Brake Caliper: Specifications Rear
Torque Specifications:
Brake Caliper Bolt ................................................................................................................................
............................................ 27 Nm (20 lb.ft.) Caliper Flow Bolt ..........................................................
.................................................................................................................... 50 Nm (37 lb.ft.) Rear
Wheel Disc Brake Adapter Nuts
............................................................................................................................................... 68 Nm
(50 lb.ft.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Page 5402
Brake Caliper: Diagrams
Part 1 Of 2
Part 2 Of 2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket
Brake Caliper: Service and Repair Brake Caliper Bracket
Removal
1. Disconnect the rear parking brake cable and conduit. 2. Remove the axle shaft.
3. WARNING: To avoid injury when using air tools, do not hold flag nuts with fingers.
Remove the bolts and the rear wheel disc brake adapter.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5405
Brake Caliper: Service and Repair Front
Anchor Plate
Removal
1. Remove the pads.
2. Remove the front disc brake caliper anchor plate.
1 Remove and discard the two front disc brake caliper anchor plate bolts.
2 Remove the front disc brake caliper anchor plate.
Installation
1. CAUTION: Use correct type and length bolts.
Follow the removal procedure in reverse order. Install new front disc brake caliper anchor plate bolts.
Overhaul
Disassembly
1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from disc brake caliper.
3. Apply low air pressure to the fluid port in the disc brake caliper.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to
the block of wood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5406
4. Remove the caliper pistons.
1 Remove the block of wood.
2 Remove the caliper pistons.
5. Remove and discard the piston seals and boots. 6. Remove and discard the bleed screw and
cap.
Assembly
1. CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper
bores.
Clean and inspect the caliper pistons and the disc brake caliper. Remove dirt and debris.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5407
- Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper
pistons.
- Clean the caliper bores with Metal Parts Brake Cleaner F3AZ-19579-SA or equivalent. Dry
thoroughly before re-assembly.
- If the caliper bores are corroded or excessively scored, replace the disc brake caliper.
- Lubricate the caliper pistons and piston seals before assembly.
2. CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3
Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If
DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4.
3. Install the caliper piston.
1 Install the piston seal.
2 Install the piston boot on the piston.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 CAUTION: Be careful not to cock the caliper piston.
Press the caliper piston into the bore.
4. Install a new bleed screw and cap. 5. Install the disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5408
Brake Caliper: Service and Repair Rear
Disassembly
1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake
caliper. 3. Secure the rear disc brake caliper in a vise.
4. Remove the rear disc brake piston.
1 Place a block of wood between the caliper bridge and the rear brake disc piston.
2 Apply low air pressure to the fluid port in the rear disc brake caliper.
3 Force the rear brake disc piston out to the block of wood.
4 Remove the block of wood and the rear brake disc piston.
5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the
rear disc brake caliper cylinder bore is
excessively scored or corroded, install a new rear disc brake caliper.
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5409
period of time.
1. Lubricate the following with Ford High Performance DOT 3 Brake Fluid C6AZ-I9542-AB or
equivalent DOT 3 fluid meeting Ford specification
ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification
SAE-J-1704-DOT 4. cylinder bore
- piston seal
- rear brake disc piston
- dust boot
2. Install the piston seal.
3. Install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
Install the rear brake disc piston.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5410
5. Install the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5411
Brake Caliper: Service and Repair Removal and Installation
Front
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, Rush eyes with running water for 15 minutes, get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, wash it with water immediately.
Disconnect the front brake hose. 1
Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5412
4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
5. Inspect the disc brake caliper.
- If leaks or damaged boots are found, disassembly is required.
Installation
1. CAUTION: Make sure guide pin boots are properly seated or damage to guide pins can occur.
NOTE: Tighten the lower caliper bolt first.
Install the disc brake caliper. 1
Install the disc brake caliper.
2 Install the disc brake caliper bolts.
2. Install the front brake hose.
- Use new copper washers; connect the front brake hose.
- Install the front brake hose bolt.
3. Bleed the caliper.
4. NOTE: After the vehicle is on the ground, if equipped with air suspension, reactivate the system
by turning on the air suspension switch.
Install the wheel and tire assembly.
5. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5413
Ford specification ESA-M6C25-A. If DOT 3 Is not available, use DOT 4 Brake Fluid meeting Ford
specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap.
6. Inspect the brake system operation.
Rear
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle
during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Disconnect the brake hose. 1
Remove bolt.
2 Disconnect the rear wheel brake hose.
3 Remove the copper washers and plug the brake hose.
4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life
and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A (Motorcraft WA- 10) or an equivalent silicone compound meeting Ford
specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide
pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin
mechanism.
Remove the rear disc brake caliper. 1
Remove the brake caliper bolts.
2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5414
5. Inspect the rear disc brake caliper for leaks.
- If leaks are found, disassembly is required.
Installation
1. Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or
damaged.
2. Position the anti-rattle clip behind the rear disc brake caliper anchor plate.
3. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct
caliper bolt.
NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the
rear disc brake caliper.
Install the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper Bracket > Page 5415
4. Install the rear wheel brake hose.
- Connect the brake hose and install the caliper flow bolt. Use new copper washers.
5. Bleed the disc brake caliper.
6. NOTE: After the vehicle is on the ground if equipped with air suspension, reactivate the system
by turning on the air suspension switch.
Install the wheel and tire assembly.
7. Verify correct brake operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Page 5416
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on
Wheels
Brake Pad: Customer Interest Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive
Brake Dust on Wheels
Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Page 5430
Brake Pad: Specifications
Front Rear
Thickness, Min. 0.039 in 0.039 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front
Brake Pad: Service and Repair Front
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Remove brake master cylinder filler cap. Check brake fluid level in brake master cylinder reservoir.
Remove fluid until brake master cylinder reservoir is half full.
2. Raise and support the vehicle. 3. Remove the wheel and tire assembly.
4. CAUTION: Replace the pad if worn to or past the specified thickness above the metal backing
plate or rivets. Replace the pads in
complete axle sets.
Inspect the pads for wear and contamination.
5. CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the pistons and
boots.
CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose.
Provide a suitable support.
Remove the disc brake caliper. 1
Remove two front disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
6. Remove the disc brake pad anti-rattle clip.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5433
7. Measure the brake disc thickness.
- Replace the brake disc if not within specification.
8. Inspect the disc brake caliper.
- If leaks or damaged boots are found, disassembly is required.
9. Remove the pads and stainless steel slippers.
1 Remove the pads and verify thickness.
2 Remove the front disc brake caliper anchor plate stainless steel slippers and discard.
10. Inspect the front disc brake anchor plate assembly.
- Check the guide pin boots for damage.
- Check the guide pins for binding and damage.
- Replace worn or damaged pins.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5434
Installation
1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining
material. Do not install contaminated
pads.
NOTE: Replace all hardware supplied with pad kit.
Install the pads. 1
Install the new front disc brake caliper anchor plate stainless steel slippers.
2 Install the pads.
2. NOTE: Use a wood block or used pad to protect pistons and boots.
Compress the caliper pistons.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5435
3. Install the disc brake pad anti-rattle clip.
4. CAUTION: Use care not to damage the bleeder screw or brake disc shield.
Install the disc brake caliper. 1
Install the disc brake caliper.
2 Install the disc brake caliper bolts.
5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Fill the brake master cylinder
reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3
fluid meeting
Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford
specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap.
8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Inspect brake operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5436
Brake Pad: Service and Repair Rear
Removal
1. Inspect the brake pads for wear or contamination. Install new if worn to or past specification.
2. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure.
Remove the rear disc brake caliper.
3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads.
Remove the brake pads by pushing inward and rotating the pad up.
4. NOTE: Use a block of wood or used pad to protect the piston and boots.
Retract the caliper piston into the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5437
5. Make sure the slippers are clean and in good condition.
Installation
1. CAUTION: Install the brake pads in full axle sets. Do not replace worn brake pads on only one
side of vehicle.
Install the brake pads.
2. Install the rear disc brake caliper. 3. Verify correct brake operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications
Brake Rotor/Disc: Specifications
Front Diameter 12.44 in
Thickness Nominal 1.1 in
Minimum 1.01 in
Minimum brake disc thickess is molded into the brake disc.
Variation, Max 0.00035 in
Maximum Runout On Vehicle 0.002 in
Hub 0.001 in
Rear Diameter 11.2 in
Thickness Nominal 0.55 in
Minimum 0.51 in
Minimum brake disc thickess is molded into the brake disc.
Variation, Max 0.0004 in
Maximum Runout On Vehicle 0.003 in
Hub Face 0.001 in
Axle Flange 0.005 in
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Brake Rotor/Disc
Brake Rotor/Disc: Service and Repair Brake Rotor/Disc
Front
Removal
1. Remove the front disc brake caliper anchor plate. 2. Locate the marked wheel stud and mark the
corresponding brake disc lug hole.
- This ensures the lowest brake disc runout is maintained during reassembly.
3. Punch out the rivet mandrel prior to drilling rivet head off.
4. CAUTION: To avoid brake disc damage, use care when drilling.
Using a 3/8 inch drill bit, drill off rivet heads.
5. CAUTION: If excessive force must be used during brake disc removal, the brake disc Total
Indicated Runout (TIR) must be checked at
installation.
NOTE: If the brake disc cannot be removed easily, apply Rust Penetrant and Inhibitor
F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A on brake disc to wheel
hub mating surfaces.
Remove the brake disc. Remove remaining rivet body from wheel hub.
Installation
1. Clean any rust or debris from brake disc and wheel hub.
- Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc and hub
surfaces.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Brake Rotor/Disc > Page 5443
2. Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford
specification ESE-M12A4-A to the hub
flange and pilot area.
3. Align the hub and brake disc marks and position the brake disc to the wheel hub.
4. Install brake disc retaining rivets. 5. Install the front disc brake caliper anchor plate. 6. Check
Total Indicated Runout (TIR).
Rear
Removal
1. CAUTION: Never allow the rear disc brake caliper to hang from the brake hose. Provide suitable
support.
NOTE: When removing the brake disc in this procedure it is not necessary to disconnect the
hydraulic lines.
Remove the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Brake Rotor/Disc > Page 5444
2. NOTE: If the brake disc binds on the rear parking brake shoe and linings, remove the adjustment
hole access plug and contract the parking brake
shoe and lining by rotating the adjuster in the loosening direction.
Remove the brake disc.
3. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc.
Measure the brake disc, and resurface as necessary. Install a new brake disc if beyond
specification.
Installation
1. Clean any rust or foreign material from the brake disc and wheel hub.
1 Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc and hub
surfaces.
2. Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford
specification ESE-M12A4-A to the hub
flange and pilot area.
3. Install the rear brake disc. 4. Install the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Brake Rotor/Disc > Page 5445
Brake Rotor/Disc: Service and Repair Disc Backing Plate
Front
Removal
1. Remove the brake disc.
2. Remove the brake disc shield.
1 Drill out three brake disc shield rivets.
2 Remove the brake disc shield.
Installation
1. Install the brake disc shield.
1 Position the brake disc shield.
2 Secure with three rivets.
2. Install the brake disc.
Rear
Removal
1. Remove the rear wheel disc brake adapter.
2. Remove the rear wheel brake disc shield.
1 Drill out the rivets.
2 Remove the rear wheel brake disc shield.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Brake Rotor/Disc > Page 5446
Installation
1. NOTE: Because the rear wheel brake disc shield is held in position by the four rear wheel disc
brake adapter bolts, new rivets are not required.
Seal the rivet holes with Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification
ESB-M4G92-A, and install the rear wheel disc brake shield.
2. Install the rear wheel disc brake adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels
Brake Shoe: Customer Interest Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on
Wheels
Brake Shoe: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 5466
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 5467
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 5473
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 5474
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure
Brake Bleeding: Service and Repair Caliper Bleeding Procedure
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the Brake Pedal (BP) and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5480
Brake Bleeding: Service and Repair Manual Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of a
new part, 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. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash
and follow the NGS instructions.
2. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the
tube in a container partially filled with clean brake fluid.
4. Have an assistant hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw
until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal,
tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5481
6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw.
8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder
screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
9. Have an assistant hold firm pressure on the brake pedal.
10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out.
While the assistant maintains pressure on the brake
pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
11. Tighten the RH front disc brake caliper bleeder screw. 12. Repeat Steps 8, 9, 10 and 11 for the
LH front disc brake caliper bleeder screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5482
Brake Bleeding: Service and Repair Master Cylinder Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can enter the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be
bled manually or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been replaced or the system has been emptied, or
partially emptied, it should be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines.
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill
the brake master cylinder reservoir with High
Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A.
4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid
flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at
the bench, install it in the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5483
6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the
brake master cylinder as follows:
1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
2 Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
3 Repeat this operation until clear, bubble-free fluid comes out.
4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5484
Brake Bleeding: Service and Repair Pressure Bleeding
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending
with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5485
Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS)
NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS)
Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened.
NOTE: Ford provides no information or procedures to bleed the brake system without the Rotunda
New Generation Star (NGS) tester/scan tool.
1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of
brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Caliper Bleeding Procedure > Page 5486
4. Tighten the RH rear bleeder screw, and disconnect the waste line.
5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder
screw, and the LH front disc brake caliper bleeder
screw, in that order.
6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the
dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps
1 through 5.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Front
Brake Caliper: Specifications Front
Torque Specifications:
Disc Brake Caliper Bolt
..........................................................................................................................................................
28-36 Nm (21-26 lb.ft.) Front Brake Hose Bolt ....................................................................................
.................................................................................. 48 Nm (35 lb.ft.) Front Disc Brake Caliper
Anchor Plate Bolt .................................................................................................................. 170-230
Nm (125-169 lb.ft.) Disc Brake Caliper Bleeder Screw
......................................................................................................................................... 17-24 Nm
(13-17 lb.ft.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Front > Page 5491
Brake Caliper: Specifications Rear
Torque Specifications:
Brake Caliper Bolt ................................................................................................................................
............................................ 27 Nm (20 lb.ft.) Caliper Flow Bolt ..........................................................
.................................................................................................................... 50 Nm (37 lb.ft.) Rear
Wheel Disc Brake Adapter Nuts
............................................................................................................................................... 68 Nm
(50 lb.ft.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Page 5492
Brake Caliper: Diagrams
Part 1 Of 2
Part 2 Of 2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket
Brake Caliper: Service and Repair Brake Caliper Bracket
Removal
1. Disconnect the rear parking brake cable and conduit. 2. Remove the axle shaft.
3. WARNING: To avoid injury when using air tools, do not hold flag nuts with fingers.
Remove the bolts and the rear wheel disc brake adapter.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5495
Brake Caliper: Service and Repair Front
Anchor Plate
Removal
1. Remove the pads.
2. Remove the front disc brake caliper anchor plate.
1 Remove and discard the two front disc brake caliper anchor plate bolts.
2 Remove the front disc brake caliper anchor plate.
Installation
1. CAUTION: Use correct type and length bolts.
Follow the removal procedure in reverse order. Install new front disc brake caliper anchor plate bolts.
Overhaul
Disassembly
1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from disc brake caliper.
3. Apply low air pressure to the fluid port in the disc brake caliper.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to
the block of wood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5496
4. Remove the caliper pistons.
1 Remove the block of wood.
2 Remove the caliper pistons.
5. Remove and discard the piston seals and boots. 6. Remove and discard the bleed screw and
cap.
Assembly
1. CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper
bores.
Clean and inspect the caliper pistons and the disc brake caliper. Remove dirt and debris.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5497
- Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper
pistons.
- Clean the caliper bores with Metal Parts Brake Cleaner F3AZ-19579-SA or equivalent. Dry
thoroughly before re-assembly.
- If the caliper bores are corroded or excessively scored, replace the disc brake caliper.
- Lubricate the caliper pistons and piston seals before assembly.
2. CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3
Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If
DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4.
3. Install the caliper piston.
1 Install the piston seal.
2 Install the piston boot on the piston.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 CAUTION: Be careful not to cock the caliper piston.
Press the caliper piston into the bore.
4. Install a new bleed screw and cap. 5. Install the disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5498
Brake Caliper: Service and Repair Rear
Disassembly
1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake
caliper. 3. Secure the rear disc brake caliper in a vise.
4. Remove the rear disc brake piston.
1 Place a block of wood between the caliper bridge and the rear brake disc piston.
2 Apply low air pressure to the fluid port in the rear disc brake caliper.
3 Force the rear brake disc piston out to the block of wood.
4 Remove the block of wood and the rear brake disc piston.
5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the
rear disc brake caliper cylinder bore is
excessively scored or corroded, install a new rear disc brake caliper.
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5499
period of time.
1. Lubricate the following with Ford High Performance DOT 3 Brake Fluid C6AZ-I9542-AB or
equivalent DOT 3 fluid meeting Ford specification
ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification
SAE-J-1704-DOT 4. cylinder bore
- piston seal
- rear brake disc piston
- dust boot
2. Install the piston seal.
3. Install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
Install the rear brake disc piston.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5500
5. Install the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5501
Brake Caliper: Service and Repair Removal and Installation
Front
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, Rush eyes with running water for 15 minutes, get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, wash it with water immediately.
Disconnect the front brake hose. 1
Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5502
4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
5. Inspect the disc brake caliper.
- If leaks or damaged boots are found, disassembly is required.
Installation
1. CAUTION: Make sure guide pin boots are properly seated or damage to guide pins can occur.
NOTE: Tighten the lower caliper bolt first.
Install the disc brake caliper. 1
Install the disc brake caliper.
2 Install the disc brake caliper bolts.
2. Install the front brake hose.
- Use new copper washers; connect the front brake hose.
- Install the front brake hose bolt.
3. Bleed the caliper.
4. NOTE: After the vehicle is on the ground, if equipped with air suspension, reactivate the system
by turning on the air suspension switch.
Install the wheel and tire assembly.
5. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5503
Ford specification ESA-M6C25-A. If DOT 3 Is not available, use DOT 4 Brake Fluid meeting Ford
specification SAE-J-1704-DOT 4. Install brake master cylinder filler cap.
6. Inspect the brake system operation.
Rear
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle
during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Disconnect the brake hose. 1
Remove bolt.
2 Disconnect the rear wheel brake hose.
3 Remove the copper washers and plug the brake hose.
4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life
and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A (Motorcraft WA- 10) or an equivalent silicone compound meeting Ford
specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide
pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin
mechanism.
Remove the rear disc brake caliper. 1
Remove the brake caliper bolts.
2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5504
5. Inspect the rear disc brake caliper for leaks.
- If leaks are found, disassembly is required.
Installation
1. Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or
damaged.
2. Position the anti-rattle clip behind the rear disc brake caliper anchor plate.
3. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct
caliper bolt.
NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the
rear disc brake caliper.
Install the rear disc brake caliper.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper Bracket > Page 5505
4. Install the rear wheel brake hose.
- Connect the brake hose and install the caliper flow bolt. Use new copper washers.
5. Bleed the disc brake caliper.
6. NOTE: After the vehicle is on the ground if equipped with air suspension, reactivate the system
by turning on the air suspension switch.
Install the wheel and tire assembly.
7. Verify correct brake operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Page 5506
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications
Brake Fluid: Specifications
Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety
Standard 116. Under this standard, brake fluids are visually different from other automotive fluids
such as transmission, power steering and engine oil.
High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Service Precautions > Technician Safety Information
Brake Fluid: Technician Safety Information
SAFETY PRECAUTIONS
WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following
actions:
^ Eye Contact - rinse eyes thoroughly with water.
^ Skin Contact - wash skin with soap and water.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Service Precautions > Technician Safety Information > Page 5512
Brake Fluid: Vehicle Damage Warnings
Use clean, fresh Ford High Performance DOT3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3
fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid
meeting Ford specification SAE-J-1704-DOT 4. These types are the only brake fluids that should
be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system.
- Do not use brake fluid that has been stored in an open container.
- Do not mix different types of brake fluid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Brake Hose
Brake Hose/Line: Specifications Brake Hose
To Caliper
Front ....................................................................................................................................................
................................................. 48 Nm (35 ft. lbs.) Rear .....................................................................
................................................................................................................................. 50 Nm (37 ft.
lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Brake Hose > Page 5517
Brake Hose/Line: Specifications Brake Line
Hydraulic Tube Connections
..........................................................................................................................................................
14-20 Nm (10-14 ft. lbs.) Front Master Cylinder Brake Tube
................................................................................................................................................ 22-28
Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Tube
................................................................................................................................................. 15-20
Nm (11-14 ft. lbs.) To ABS Brake Pressure Control Valve Block
.......................................................................................................................................... 17 Nm (12
ft. lbs.)
NOTE: All hydraulic tubes must be tightened to the specific torque value and be free of fluid
leakage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Description and Operation > Brake Hose
Brake Hose/Line: Description and Operation Brake Hose
CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which could
result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly
double flared to provide strong leakproof connections. When bending the tubing to fit the
underbody or rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be replaced with a tube of the same
type, size, shape and length.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely.
After replacement, bleed the brake system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Description and Operation > Brake Hose > Page 5520
Brake Hose/Line: Description and Operation Brake Line
CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which could
result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly
double flared to provide strong leakproof connections. When bending the tubing to fit the
underbody or rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be replaced with a tube of the same
type, size, shape and length.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely.
After replacement, bleed the brake system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications
Brake Proportioning/Combination Valve: Specifications
Brake Fluid Control Valve
.............................................................................................................................................................
13-24 Nm (10-17 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications > Page 5524
Brake Proportioning/Combination Valve: Description and Operation
The brake pressure control valve proportions the pressure to the rear brakes. When the brake pedal is applied, brake fluid pressure passes through the proportioning valves to
the rear brake system until the valve split point is reached.
- Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Mounting Bolts .....................................................................................................................................
......................................... 15-17 Nm (11-12 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 5528
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 5529
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Removal
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contract with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
1. Disconnect the battery ground cable.
2. NOTE: Plug each port of the Hydraulic Control Unit (HCU) to prevent brake fluid from spilling.
Disconnect the brake lines.
3. Disconnect the anti-lock brake control module electrical connectors.
4. Remove the mounting bracket to HCU bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 5530
5. Remove the anti-lock brake control module.
1 Remove the screws.
2 Remove the module.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
NOTE: Bleed brake system as necessary.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications
Brake Master Cylinder: Specifications
Brake Master Cylinder Nuts
...........................................................................................................................................................
21-29 Nm (16-21 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Description and Operation > Brake Fluid Reservoir
Brake Master Cylinder: Description and Operation Brake Fluid Reservoir
NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder,
new grommets must be installed.
The brake master cylinder reservoir: is mounted to the brake master cylinder.
- holds fluid supply for each brake master cylinder hydraulic piston.
- provides visual fluid level markings.
- contains the brake master cylinder fluid level sensor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Description and Operation > Brake Fluid Reservoir > Page 5536
Brake Master Cylinder: Description and Operation Master Cylinder, Brakes
The brake master cylinder is a dual piston type. The brake master cylinder operates as follows: When the brake pedal is depressed, pressure is applied by mechanical linkage to the primary and
secondary piston.
- Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits.
- ABS brake master cylinder will not be overhauled, due to internal adjustments which require
extensive special tools and fixtures. Service is made by replacement only.
The brake master cylinder consists of brake master cylinder reservoir
- brake master cylinder body
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Brake Master Cylinder: Initial Inspection and Diagnostic Overview
Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the brake
system. Refer to the symptom chart for abnormal condition diagnosis.See: Testing and
Inspection/Symptom Related Diagnostic Procedures
Normal Conditions
The following conditions are considered normal and are not indications that the brake master
cylinder is in need of service.
Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake
master cylinder reservoir will rise during brake application and fall during release. The net fluid level
(i.e., after brake application and release) will remain unchanged.
Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting
flange. This results from the normal lubricating action of the master cylinder bore and seal.
Condition 3: Fluid level will decrease with pad wear.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5539
Brake Master Cylinder: Component Tests and General Diagnostics
Bypass Condition Test
1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake
master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master
cylinder has an internal leak and must be rebuilt or installed new.
Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional
brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the
brake lines to the brake master cylinder to enter the brake master cylinder reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir.
Turbulence seen in the brake master cylinder reservoir upon application or release of the brake
pedal is normal and shows that the compensating ports are not plugged.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 5540
Brake Master Cylinder: Adjustments
1. Remove the brake master cylinder.
2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster.
Adjust the power brake booster-to-brake master cylinder push rod, vacuum applied. 1
Measure the power brake booster-to-brake master cylinder push rod.
2 If necessary, adjust the screw to the correct length.
3. Install the brake master cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir
Brake Master Cylinder: Service and Repair Brake Fluid Reservoir
Removal
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
1. Disconnect the brake master cylinder fluid level switch. 2. Use a suitable suction device to drain
the brake master cylinder reservoir.
3. Carefully pry up on the brake master cylinder reservoir and remove.
Installation
1. NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets.
Install the brake master cylinder reservoir. 1
Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or
equivalent fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4
Brake Fluid meeting Ford specification SAE-J-I704-DOT 4. Insert the grommets into the brake
master cylinder.
2 Press the brake master cylinder reservoir into the grommets until it is fully seated.
3 Connect the brake master cylinder fluid level switch.
4 Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not
available, use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir > Page 5543
Brake Master Cylinder: Service and Repair Master Cylinder, Brakes
Removal
1. Disconnect the brake tubes.
2. Disconnect the brake master cylinder fluid level switch connector.
3. Remove the brake master cylinder nuts.
4. Remove the wiring harness bracket and position aside. 5. Remove the brake master cylinder.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir > Page 5544
1. Follow the removal procedure in reverse order,
- Bleed the brake system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Specifications
Parking Brake Cable: Specifications
Rear Cable and Conduit Retaining Bolts
......................................................................................................................................... 12-15 Nm
(9-11 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front
Parking Brake Cable: Service and Repair Front
Removal
1. Release the parking brake control, using the parking brake release handle.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Raise the vehicle on a hoist.
3. Pull the parking brake adjuster clip downward. 4. Apply the parking brake control fully.
5. Push up on the parking brake adjuster clip to lock the adjuster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5551
6. Release the parking brake control, using the parking brake release handle.
7. Disconnect the front parking brake cable and conduit from the LH parking brake rear cable and
conduit at the cable connector.
8. Press the retaining tabs, and remove the front parking brake cable and conduit retainer from the
frame.
9. Remove the screw retaining the inner front fender apron to the frame.
10. Pullback the front fender apron to expose the front parking brake cable and conduit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5552
11. Pull the front parking brake cable and conduit through the frame, and let it hang in the wheel
housing. 12. Lower the vehicle.
13. Remove the instrument close-out panel pushpins, and remove the panel.
14. Disconnect the front parking brake cable and conduit from the parking brake control.
15. Push the front parking brake cable and conduit down, and remove the front parking brake cable
and conduit from inside the wheel housing.
Installation
1. Install the front parking brake cable and conduit through the dash panel from inside the wheel
housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5553
2. Connect the front parking brake cable and conduit to the parking brake control.
3. Install the instrument close-out panel and the pushpins. 4. Raise the vehicle.
5. Install the front parking brake cable and conduit through the frame.
6. Position the front fender apron, and install the retaining screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5554
7. Install the front parking brake cable and conduit retainer to the frame.
8. Connect the front parking brake cable and conduit to the LH parking brake rear cable and
conduit at the cable connector. 9. Adjust the cable tension.
10. Turn the air suspension switch on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5555
Parking Brake Cable: Service and Repair Rear
Removal
1. Release the parking brake control, using the parking brake release handle.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Raise the vehicle on a hoist.
3. Pull the parking brake adjuster clip downward. 4. Lower the vehicle. 5. Apply the parking brake
control fully. 6. Raise the vehicle.
7. Push up on the parking brake adjuster clip to lock the adjuster. 8. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5556
9. Release the parking brake control, using the parking brake release handle.
10. Raise the vehicle.
11. Disconnect the front parking brake cable and conduit from the parking brake rear cable and
conduit at the cable connector.
12. Press the retaining tabs, and remove the RH parking brake rear cable and conduit from the
frame.
13. Disconnect the LH parking brake rear cable and conduit retainer from the cable adjuster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5557
14. Remove the RH parking brake rear cable and conduit retainer bolts.
15. Compress the cable retaining clip, and pull the parking brake rear cable and conduit out of the
rear disc brake adapter plate.
16. Disconnect the parking brake rear cable and conduit from the parking brake lever.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5558
17. Unclip the parking brake rear cable and conduit from the axle housing. 18. Remove the parking
brake rear cable and conduit.
Installation
1. Install the parking brake rear cable and conduit.
2. Connect the parking brake rear cable and conduit to the parking brake lever.
3. Install the parking brake rear cable and conduit in the rear disc brake adapter plate.
4. Clip the RH parking brake rear cable and conduit to the axle housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5559
5. Install the RH parking brake rear cable and conduit retainer bolts.
6. Install the RH parking brake rear cable and conduit to the frame.
7. Connect the LH parking brake rear cable and conduit retainer to the cable adjuster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front > Page 5560
8. Connect the front parking brake cable and conduit to the parking brake rear cable and conduit at
the cable connector. 9. Adjust the cable tension.
10. Turn the air suspension switch on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications
Parking Brake Control: Specifications
Parking Brake Control-to-Body Bolts
............................................................................................................................................ 25-35 Nm
(19-25 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5564
Parking Brake Control: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Release the parking brake control, using the parking brake release handle.
3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Raise the vehicle on the hoist.
4. Pull the parking brake adjuster clip downward. 5. Apply the parking brake control fully.
6. Push up on the parking brake adjuster clip to lock the adjuster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5565
7. Release the parking brake control, using the parking brake release handle.
8. Disconnect the front parking brake cable and conduit from the cable connector. 9. Lower the
vehicle.
10. Unclip the scuff plate and the cowl side trim panel, and remove.
11. Remove the instrument close-out panel pushpins, and remove the panel.
12. Disconnect the parking brake release handle cable from the parking brake control.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5566
13. Remove the retaining screws and the instrument panel steering column cover with the parking
brake release handle.
14. Remove the retaining bolts and the instrument panel steering column opening cover
reinforcement.
15. In the engine compartment, loosen the Powertrain Control Module (PCM) wiring connector
retaining bolt and disconnect the connector.
16. Remove the instrument panel wiring connector retaining bolt, and disconnect the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5567
17. Remove the shake brace to parking brake control bolt. 18. From under the instrument panel,
remove the Powertrain Control Module (PCM).
19. Remove the instrument panel retaining bolts.
20. Pull the instrument panel slightly rearward, and retain it using a small block of wood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5568
21. Remove the parking brake release vacuum hose from the parking brake release control motor.
22. Disconnect the electrical connector from the parking brake switch.
23. Disconnect the front parking brake cable and conduit from the parking brake control.
24. Remove the parking brake control retaining bolts. 25. Remove the parking brake control.
Installation
1. Position the parking brake control.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5569
2. Install the parking brake control retaining bolts.
3. Connect the front parking brake cable and conduit to the parking brake control.
4. Connect the electrical connector to the parking brake switch.
5. Install the parking brake release vacuum hose to the parking brake release control motor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5570
6. Pull the instrument panel slightly rearward, and remove the wood block.
7. Install the instrument panel retaining bolts.
8. Install the shake brace bolt. 9. Install the Powertrain Control Module (PCM).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5571
10. Connect the instrument panel wiring connector, and install the retaining bolt.
11. Connect the Powertrain Control Module (PCM) wiring connector, and install the retaining bolt.
12. Install the instrument panel steering column opening cover reinforcement and the retaining
bolts.
13. Install the instrument panel steering column cover, parking brake release handle and retaining
screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 5572
14. Connect the parking brake release handle cable to the parking brake control.
15. Install the instrument close-out panel, and install the pushpins.
16. Install the cowl side trim panel and scuff plate. 17. Raise the vehicle.
18. Connect the front parking brake cable and conduit to the cable connector. 19. Adjust the
parking brake cable tension. 20. Connect the battery ground cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Specifications
Parking Brake Lever: Specifications
Release Handle Mounting Screw.........................................................................................................
.............................................. 1-2 Nm (9-17 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor >
Component Information > Specifications
Parking Brake Release Motor: Specifications
Retaining Screw ..................................................................................................................................
.................................................... 3 Nm (26 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair
Parking Brake Shoe: Service and Repair
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the tire and wheel assembly. 3. Remove the brake disc.
4. Remove the brake shoe adjusting screw spring.
5. Remove the brake shoe adjustment screw.
6. Remove the brake shoe hold down springs. 7. Remove the parking brake shoe and linings. 8.
Inspect the components for excessive wear or damage, and install new components as required.
Installation
1. Follow the removal procedure in reverse order.
- Lubricate the brake shoe contact point before installation of the rear brake shoes, using Silicone
Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A) (Motorcraft WA-10) or an
equivalent silicone compound meeting Ford specification ESE-M1C171-A.
- Use a brake adjusting gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020
inch) less than the inside diameter of the drum portion of the brake disc.
- Adjust the parking brake cable tension.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation
Vacuum Brake Booster: Description and Operation
The power brake booster: is a dual diaphragm, vacuum assisted power brake booster.
- reduces brake pedal pressure and travel distance.
- is located on the LH side of the bulkhead in the engine compartment, between the brake pedal
and brake master cylinder.
- is divided into separate chambers by the diaphragm.
- Will not operate if vacuum is restricted or if any of the vacuum-related power brake components
fail.
- is replaced as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
The power brake booster check valve: is located on the front of the power brake booster.
- is positioned between the power brake booster and the power brake booster vacuum hose.
- closes when the engine is turned off.
- in the closed position, traps engine vacuum in the power brake booster.
- retains vacuum to provide several power assisted brake applications with the engine off.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Page 5586
Vacuum Brake Booster: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Disconnect the fluid level sensor connector.
3. Position the speed control cable out of the way.
4. Disconnect the power brake booster check valve.
5. Remove the brake master cylinder nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Page 5587
6. Remove the wiring harness bracket, and position aside.
7. Remove the brake master cylinder and position aside.
8. Remove the instrument close-out panel pushpins, and then remove the panel.
9. Remove the stoplight switch retaining pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Page 5588
10. Slide the stoplight switch and booster push rod off the brake pedal pin.
11. Remove the brake booster retaining nuts.
12. Remove the power brake booster.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Page 5589
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock
Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications
Anti-Lock Brake Control Module: Specifications
Retaining Screws .................................................................................................................................
................................................................. 1.8-2.8 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock
Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5594
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock
Brake Control Module <--> [Electronic Brake Control Module] > Component Information > Specifications > Page 5595
Anti-Lock Brake Control Module: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Disconnect the anti-lock brake control module electrical connectors.
- Disconnect the control module electrical connector.
- Disconnect the pump motor electrical connector.
3. Remove the anti-lock brake control module.
1 Remove the screws.
2 Remove the module.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Measured using Rotunda EEC-IV 60-Pin Breakout Box
Front and Rear 800-1400 ohms
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5601
Wheel Speed Sensor: Mechanical Specifications
Retaining Bolts Front 36-53 in.lb
Rear 14-19 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front
Wheel Speed Sensor: Service and Repair Front
Removal
1. Disconnect the front anti-lock brake sensor electrical connector. 2. Raise and support the
vehicle.
3. Remove the routing clips.
4. Remove the front anti-lock brake sensor.
1 Remove the bolt.
2 Remove the sensor.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 5604
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 5605
Wheel Speed Sensor: Service and Repair Rear
Removal
1. Remove rear seat bottom.
2. Disconnect the rear anti-lock brake sensor electrical connector.
3. Push the sensor harness grommet through the passenger compartment floor. 4. Raise and
support the vehicle.
5. Disconnect the routing clips.
6. Remove the rear anti-lock brake sensor.
1 Remove the bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 5606
2 Remove the sensor.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available
Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 5614
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 5615
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 5616
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 5617
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages
Available > Page 5618
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5619
Ignition Switch Lock Cylinder: Specifications
Lock Cylinder Housing Screws ............................................................................................................
.................................................... 22 Nm (16 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional
Ignition Switch Lock Cylinder: Service and Repair Functional
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5622
Ignition Switch Lock Cylinder: Service and Repair Non-Functional
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5623
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the steering column lock housing bearing and steering column lock gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
1. Install the steering column lock gear and bearing.
^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification
ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing
bearing.
^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three
o'clock position. Rotate it counterclockwise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5624
2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install
the steering wheel.
4. Install the ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 5632
The Starter Relay is located in the High Current Relay Center.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 5633
Starter Relay: Description and Operation
The starter relay:
- is a mini ISO relay.
- switches power to the starter solenoid to engage the starter motor when it receives a START
signal from the ignition switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 5634
Starter Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 5635
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 5636
Starter Relay: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Press the clips inward and open the relay junction box.
3. Remove the ISO starter relay.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications
Battery Cable: Specifications
Battery Ground Cable Bolt 7-10 Nm
Battery Ground Cable 7-10 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications >
Page 5641
Battery Cable: Description and Operation
Vehicles are equipped with a 12 volt maintenance-free battery.
WARNING
- BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL
INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO
COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS
SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.
- WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE
ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH
A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.
- KEEP BATTERIES OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC
ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN
WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE
ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH
IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL
ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized
recycling facility for disposal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Generator Output .................................................................................................................................
................................................................... 130 Amps
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 5647
Alternator: Mechanical Specifications
Pulley Ratio
Generator Pulley Ratio ........................................................................................................................
.......................................................................... 2.72:1
Torque Specifications
Generator Support Bracket Bolts
..................................................................................................................................................... 8-12
Nm (71-106 Lb-In) Generator Mounting Bolts .....................................................................................
........................................................................... 20-30 Nm (15-22 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 5648
Alternator: Application and ID
Generator
Type
..........................................................................................................................................................
6-G With Internal Mounted Voltage Regulator Generator ...................................................................
......................................................................................................................................... F6AU-CA
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 5649
Alternator: Description and Operation
The generator has an internal voltage regulator that is not serviced separately. The generator and
voltage regulator are serviced as an assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 5650
Alternator: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the engine cover.
1. Remove the screw. 2. Push the cover forward to disengage the front clips, then lift the engine
cover straight up.
3. Remove the pushpins and the wiring harness.
4. Remove the four bolts and the generator bracket.
5. Disconnect the electrical connectors. 6. Release the belt tension.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 5651
7. Release the belt from the Generator (GEN).
8. Remove the generator.
1. Loosen the bolts. 2. Pull the generator straight up to remove.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Application and ID
Voltage Regulator: Application and ID
Voltage Regulator Type
...................................................................................................................................................
Electronic Integral With Generator
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available
Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5661
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5662
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5663
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5664
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5665
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Page 5666
Ignition Switch Lock Cylinder: Specifications
Lock Cylinder Housing Screws ............................................................................................................
.................................................... 22 Nm (16 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Functional
Ignition Switch Lock Cylinder: Service and Repair Functional
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Functional > Page 5669
Ignition Switch Lock Cylinder: Service and Repair Non-Functional
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Functional > Page 5670
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the steering column lock housing bearing and steering column lock gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
1. Install the steering column lock gear and bearing.
^ Use Ignition Lock Grease FOAZ-19584-A or equivalent meeting Ford specification
ESA-M1C232-A to coat the steering column lock gear and the steering column lock housing
bearing.
^ The narrow section of the keyhole must be in the one o'clock, with the tab inboard at the three
o'clock position. Rotate it counterclockwise.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Functional > Page 5671
2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install
the steering wheel.
4. Install the ignition switch lock cylinder.
^ Verify ignition switch lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Cable: Customer Interest Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition >
Page 5683
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition
Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition > Page 5689
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component
Information > Testing and Inspection
Starter Drive/Bendix: Testing and Inspection
1. Remove the starter motor.
2. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear
pattern is normal, install the starter motor.
3. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B)
milled or damaged, replace the starter motor.
Replace the flywheel ring gear.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 5697
The Starter Relay is located in the High Current Relay Center.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 5698
Starter Relay: Description and Operation
The starter relay:
- is a mini ISO relay.
- switches power to the starter solenoid to engage the starter motor when it receives a START
signal from the ignition switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 5699
Starter Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 5700
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 5701
Starter Relay: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Press the clips inward and open the relay junction box.
3. Remove the ISO starter relay.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Specifications
Starter Solenoid: Specifications
Starter Solenoid Terminal Nuts
............................................................................................................................................................
5-7 Nm (45-61 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5710
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5711
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5712
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5713
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5714
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5715
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5716
Circuit Breaker: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5717
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5718
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5719
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5720
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5721
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Diagram Information and Instructions > Page 5722
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions
Electrical Accessory Panel: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5727
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5728
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5729
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5730
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5731
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5732
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5733
Electrical Accessory Panel: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5734
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5735
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5736
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5737
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5738
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 5739
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5748
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5749
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5750
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5751
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5752
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5753
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5754
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5755
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5761
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5762
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5763
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5764
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5765
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5766
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5767
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5768
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Battery Junction Box
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Battery Junction Box > Page 5773
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5776
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5777
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5778
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5779
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5780
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5781
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5782
Fuse: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5783
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5784
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5785
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5786
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5787
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 5788
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Battery Junction Box
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Battery Junction Box > Page 5791
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5796
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5797
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5798
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5799
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5800
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5801
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5802
Fuse Block: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5803
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5804
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5805
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5806
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5807
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5808
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection > Page 5812
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection > Page 5816
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5821
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5822
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5823
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5824
Multiple Junction Connector: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5825
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5826
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5827
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5828
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5829
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5830
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5831
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5832
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5833
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5834
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5835
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5836
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5837
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5838
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5839
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5840
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5841
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5842
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5843
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5844
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5845
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C102 > Page 5846
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5851
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5855
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 5860
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 5861
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > High Current Relay Center
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > High Current Relay Center > Page 5866
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > High Current Relay Center > Page 5867
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5873
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5874
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5875
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5876
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5877
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5878
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5879
Circuit Breaker: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5880
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5881
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5882
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5883
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5884
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams >
Diagram Information and Instructions > Page 5885
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions
Electrical Accessory Panel: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5890
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5891
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5892
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5893
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5894
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5895
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5896
Electrical Accessory Panel: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5897
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5898
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5899
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5900
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5901
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 5902
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5911
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5912
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5913
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5914
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5915
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5916
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5917
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5918
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5924
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5925
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5926
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5927
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5928
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5929
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5930
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 5931
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction
Box
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction
Box > Page 5936
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions
Fuse: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5939
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5940
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5941
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5942
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5943
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5944
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5945
Fuse: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5946
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5947
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5948
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5949
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5950
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 5951
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery
Junction Box
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery
Junction Box > Page 5954
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5959
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5960
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5961
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5962
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5963
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5964
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5965
Fuse Block: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5966
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5967
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5968
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5969
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5970
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5971
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection > Page 5975
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection > Page 5979
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5984
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5985
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5986
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5987
Multiple Junction Connector: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5988
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5989
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5990
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5991
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5992
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5993
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5994
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5995
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C102 > Page 5996
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ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
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Schematic
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Component Testing Procedure
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
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Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
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Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
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^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
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Comprehensive Noise/Vibration/Harshness Procedure > Page 6126
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Comprehensive Noise/Vibration/Harshness Procedure > Page 6127
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Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
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Comprehensive Noise/Vibration/Harshness Procedure > Page 6129
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
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Comprehensive Noise/Vibration/Harshness Procedure > Page 6130
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 6131
Alignment: Specifications
NOTE: All specifications are given for a vehicle at curb load.
CAMBER:
Nominal ...............................................................................................................................................
..................................................................... -0.50° Tolerance ............................................................
.....................................................................................................................................................
±0.75° Difference/Split (Left Minus Right)
Nominal ...............................................................................................................................................
................................................................ 0.00° Tolerance ..................................................................
......................................................................................................................................... ±0.75°
CASTER:
Nominal ...............................................................................................................................................
.................................................................... +5.50° Tolerance ............................................................
.....................................................................................................................................................
±0.75° Difference/Split (Left Minus Right)
Nominal ...............................................................................................................................................
................................................................ +0.5° Tolerance ..................................................................
......................................................................................................................................... ±0.75°
TOTAL TOE [a]
Degree:
Nominal ...............................................................................................................................................
............................................................. -0.125° Tolerance ..................................................................
......................................................................................................................................... ±0.25°
CLEAR VISION [b]:
Nominal ...............................................................................................................................................
....................................................................... -2.0° Tolerance ............................................................
.......................................................................................................................................................
±3.0°
RIDE HEIGHT
Base
Front ....................................................................................................................................................
........................ 29.6 ±12.7 mm (1.2 ±0.5 inch) Rear ...........................................................................
................................................................................................ 138.0 ±7.60 mm (5.4 ±0.3 inch)
Air Suspension
Front ....................................................................................................................................................
........................ 27.4 ±12.7 mm (1.1 ±0.5 inch) Rear ...........................................................................
.................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch)
With Handling package
Front ....................................................................................................................................................
........................ 26.0 ±12.7 mm (1.0 ±0.5 inch) Rear ...........................................................................
.................................................................................................. 132.4 ±7.6 mm (5.2 ±0.3 inch)
Police/NGV
Front ....................................................................................................................................................
........................ 26.4 ±12.7 mm (1.0 ±0.5 inch) Rear ...........................................................................
.................................................................................................. 132.3 ±7.6 mm (5.2 ±0.3 inch)
VEHICLE LEAN (Side to Side Height Difference)
Front ....................................................................................................................................................
................................................ 12.7 mm (0.5 inch) Rear .....................................................................
................................................................................................................................ 12.7 mm (0.5
inch)
[a] Positive value is toe-in, negative value is toe-out. [b] Position of steering wheel spoke to
horizontal. Negative value specification is counterclockwise.
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
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Alignment: Description and Operation
Camber and caster are adjusted by means of two adjustment cams located on each upper control
arm. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve.
CAMBER
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
CASTER
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
TOE
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Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
RIDE HEIGHT
Front Ride Height Measurement
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Rear Ride Height Measurement
On vehicles equipped with an air suspension system, the vehicle ride height can only be measured
accurately after the accurate trim test has been executed using a NGS tester.
Wheel Track
WHEEL TRACK
Refer to image provided.
DOGTRACKING
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Dogtracking
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
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.
SHIMMY
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
NIBBLE
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces and observed by the driver as small rotational oscillations of the steering wheel.
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 the steering correction is completed.
DRIFT/PULL
Pull is 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 hands off the steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road crown).
POOR GROOVE FEEL
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^
Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the
steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the
self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and
Camber
Alignment: Service and Repair Caster and Camber
1. Loosen the nuts.
2. To adjust the camber, rotate the adjustment cam.
^ To increase camber, rotate the adjustment cam clockwise.
^ To decrease camber, rotate the adjustment cam counterclockwise.
3. To adjust the caster, rotate the adjustment cam.
^ To increase the caster, rotate the adjustment cam clockwise.
^ To decrease the caster, rotate the adjustment cam counterclockwise.
4. Hold each cam and tighten the nuts. 5. Recheck the camber and caster. Follow the
manufacturer's instructions. Readjust the camber and caster as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and
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Alignment: Service and Repair Toe
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Check the toe settings. Follow the manufacturer's instructions.
4. Loosen the nuts.
^ Clean-and lubricate the steering linkage and tie rod end threads.
5. Rotate the adjusting sleeves to obtain the correct toe setting.
6. Position the adjusting sleeve clamps within the horizontal and vertical limits shown. Tighten the
nuts. 7. Recheck the toe settings. Follow the manufacturer's instructions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information >
Locations
Electronic Variable Orifice Steering Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information >
Locations > Page 6144
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Electronic Variable Orifice Steering Module <--> [Steering Control Module] > Component Information >
Locations > Page 6145
Electronic Variable Orifice Steering Module: Service and Repair
Removal
1. Lower the panel.
2. Remove the lamp from the panel and disconnect the wiring.
3. Remove the screws.
4. Disconnect the wiring and remove the control module.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6150
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6151
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Retaining Screws .................................................................................................................................
..................................... 2.3-3.3 Nm (20-29 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6155
Suspension Control Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6156
Suspension Control Module: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6157
Suspension Control Module: Description and Operation
A microprocessor controls the air suspension system. The microprocessor and its supporting
hardware are contained in the air suspension control module. The air suspension control module
responds to signals from various sensors in the vehicle to maintain the programmed ride height
while the vehicle is either moving or stopped. The air suspension control module accomplishes this
by opening and closing solenoid valves to control the amount of air in the air spring(s). The air
suspension control module turns on the compressor by applying voltage through the compressor
relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the
vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs
from the air suspension height sensor(s).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6158
Suspension Control Module: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Pull out the lower instrument panel insulator.
1 Remove the pushpins.
2 Pull out the lower instrument panel insulator.
4. Remove the lower instrument panel insulator.
1 Disconnect the power point.
2 Disconnect the courtesy lamp.
3 Remove the lower instrument panel insulator.
5. Remove the rear air suspension control module.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the rear air suspension control module.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6159
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6165
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6166
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6167
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications
Ride Height Sensor: Specifications
Mounting Bracket To Lateral Arm
...........................................................................................................................................................
14 Nm (10 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6172
Ride Height Sensor: Description and Operation
The air suspension height sensor sends signals to the air suspension control module. There are
three possible conditions that the air suspension control module interprets from the signals of the
air suspension height sensors. The conditions are trim height, below trim height, or above trim
height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6173
Ride Height Sensor: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support
the vehicle.
4. Disconnect the air suspension height sensor electrical connector.
5. Remove the air suspension height sensor.
^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball
studs.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6177
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6178
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6179
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation
Suspension Mode Switch: Description and Operation
CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is
hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of
the system and possible damage to the air suspension system components.
The air suspension switch provides a signal to the air suspension control module in the ON position
to activate the system to maintain the programmed vehicle height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation > Page 6183
Suspension Mode Switch: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Peel back the luggage compartment trim.
1 Remove the pushpins.
2 Peel back the luggage compartment trim.
4. Remove the air suspension switch.
1 From behind the quarter panel reinforcement, depress the clips.
2 Remove the air suspension switch.
5. Disconnect the electrical connector.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and
Repair
Center Link: Service and Repair
Removal
1. Raise and support the vehicle.
2. NOTE: Both the left side and the right side inner tie-rod ends are removed the same way. Only
the left side is shown.
Remove the nut. 1
Remove the cotter pin.
2 Remove the nut.
3. Using the special tool, remove the tie-rod end from the steering sector shaft arm drag link.
4. Remove the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and
Repair > Page 6188
5. Using the special tool, disconnect the steering gear sector shaft arm from the steering sector
shaft arm drag link.
6. Remove the nut.
1 Remove the cotter pin.
2 Remove the nut and washer.
7. Remove the steering sector shaft arm drag link.
Installation
NOTE: Before installing the idler arm to the drag link, make sure the idler arm is in the straight
ahead position (parallel to the vehicle's centerline).
1. Install the steering sector shaft arm drag link onto the steering idler arm and bracket.
2. Install the washer, nut and a new cotter pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and
Repair > Page 6189
3. Install the steering gear sector shaft arm onto the steering sector shaft arm drag link. Install a
new lock nut.
4. NOTE: Both the left side and the right side inner tie-rod ends are installed the same way. Only
the left side is shown.
Install the tie-rod end, nut and a new cotter pin.
5. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and
Repair > Page 6190
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information
> Locations
Diagnostic Connector: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information
> Locations > Page 6194
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications
Idler Arm: Specifications
Retaining Bolts ....................................................................................................................................
..................................................... 80 Nm (59 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications >
Page 6198
Idler Arm: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the nut.
1 Remove the cotter pin.
2 Remove the nut and washer.
3. Remove the steering sector shaft arm drag link.
4. Remove the steering idler arm and bracket.
1 Remove the bolts, washers and nuts.
2 Remove the steering idler arm and bracket.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications >
Page 6199
1. NOTE: Before installing the idler arm to the drag link, make sure the idler arm is in the straight
ahead position (parallel to the vehicle's
centerline).
Install the steering idler arm and bracket, bolts, washers and nuts.
2. Position the steering sector shaft arm drag link onto the steering idler arm and bracket.
3. Install the washer, nut and a new cotter pin. 4. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical
Service Bulletins > Steering - Pitman Arm Inspection Tip
Pitman Arm: Technical Service Bulletins Steering - Pitman Arm Inspection Tip
Article No. 99-21-9
10/18/99
STEERING - PITMAN ARM INSPECTION - SERVICE TIP
FORD: 1998-2000 CROWN VICTORIA
LINCOLN: 1998-2000 TOWN CAR
MERCURY: 1998-2000 GRAND MARQUIS
ISSUE The Workshop Manuals for 1998-2000 Crown Victoria/Grand Marquis and Town Car do not
contain a procedure for inspecting the pitman arm ball joint for wear.
ACTION The pitman arm ball joint on 1998-2000 Crown Victoria/Grand Marquis and Town Car
vehicles can be inspected by referring to the following Inspection Procedure.
INSPECTION PROCEDURE
1. Raise vehicle on hoist.
2. Visually inspect the pitman arm ball joint seal. If it is cut or torn, replace the pitman arm (refer to
the appropriate Workshop Manual for pitman arm service procedure).
3. Pull down on the centerlink to take any play out of the pitman arm ball joint. Measure the
distance from the top of the pitman arm forging to the bottom of the centerlink using digital calipers.
Attach a C-clamp between the top of the pitman arm ball joint socket and the pitman arm ball stud.
Tighten the C-clamp to fully compress the ball joint and measure from the top of the pitman arm
forging to the bottom of the centerlink again. Subtract the second measurement from the first to get
the total movement.
4. If more than 2.78 mm (0.110") movement is measured, replace the pitman arm (refer to the
appropriate Workshop Manual for service procedure).
5. The nut attaching the pitman arm to the centerlink can be reused.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 303000, 304000, 390000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical
Service Bulletins > Page 6204
Pitman Arm: Specifications
Retaining Nut
To Sector Shaft ....................................................................................................................................
.............................................. 305 Nm (225 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical
Service Bulletins > Page 6205
Pitman Arm: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the nuts.
1 Remove the nut.
2 Remove the nut and the lockwasher.
3. Using the special tool, disconnect the steering gear sector shaft arm from the steering sector
shaft arm drag link.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical
Service Bulletins > Page 6206
4. Scribe an alignment mark on both the steering gear sector shaft arm and the shaft.
5. Using the special tool, remove the steering gear sector shaft arm.
Installation
1. Install the steering gear sector shaft arm.
1 Align the mark on the steering gear sector shaft arm with the alignment mark on the shaft.
2 Install the steering gear sector shaft arm.
3 Install a new lockwasher and nut. Do not tighten the nut.
2. Install the steering gear sector shaft arm onto the steering sector shaft arm drag link. Install the
nut and a new lock nut. 3. Lower the vehicle. 4. Check the wheel alignment. Adjust as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical
Service Bulletins > Page 6207
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
NOTE: If the air is not purged from the power steering system correctly, pump failure could result.
This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that
have had steering component repairs.
A whine heard from the power steering pump may be caused by air in the system. The power
steering purging procedure must be performed under the following conditions: ^
Prior to any component repair for which power steering noise complaints are accompanied by
evidence of aerated fluid.
^ After replacement of any power steering system component (gear, hose, etc.).
1. Remove the power steering fluid reservoir cap.
2. Tightly insert the stopper of vacuum pump into the power steering fluid reservoir. 3. Start the
engine and allow it to idle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 6212
4. Using the special tool, apply the maximum vacuum for a minimum of three minutes with the
engine at idle. Maintain the maximum vacuum with
vacuum pump.
5. Release the vacuum source and remove vacuum pump.
6. Add fluid to the center mark of the power steering fluid reservoir.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 6213
7. Using the special tool, reinstall vacuum pump stopper and apply maximum vacuum.
8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds
at a time. Damage to the power steering
pump will occur.
Cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes.
9. Stop the engine, release the vacuum source, and remove vacuum pump.
10. Add power steering fluid if necessary. Install the power steering fluid reservoir cap.
11. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds
at a time. Damage to the power steering
pump will occur.
Start the engine and cycle the steering wheel from stop to stop every 30 seconds for approximately
five minutes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 6214
12. Check for power steering fluid leaks at all connections. If the power steering fluid still shows
signs of aeration, repeat this procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER
STEERING SYSTEMS
FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort
2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle
2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53
Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005
Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007
Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series
2000-2007 F-650, F-750 2006-2007 Low Cab Forward
LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln
LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator
2006-2007 Mark LT 2007 MKX
MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar
2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002
Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid for power steering systems originally requiring MERCON(R).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 6219
ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be
serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids
labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission
Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining
inventory has been depleted.
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V.
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER
STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY
OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Page 6220
Power Steering Fluid: Specifications
Use Motorcraft MERCON(r) Multi-Purpose ATF, XT-2-QDX or equivalent MERCON(r) approved
fluid.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Page 6221
Power Steering Fluid: Service Precautions
CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may
result.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair
Power Steering Fluid Cooler: Service and Repair
Removal
1. Remove the air cleaner assembly.
2. Remove the bolt and the bracket. Repeat on the opposite side.
3. Disconnect the hoses.
4. Disconnect the hoses.
5. Remove the bolt. Repeat on the opposite side. 6. Push back on the radiator and remove the
power steering fluid cooler.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair > Page 6225
1. Follow the removal procedure in reverse order. 2. Fill and leak check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair
Power Steering Fluid Reservoir: Service and Repair
Removal
1. Drain the reservoir using a hand suction pump. 2. Position a drain pan.
3. Disconnect the power steering reservoir pump hose and the power steering return hose.
4. Remove the screw.
5. Remove the screws and the power steering pump reservoir.
Installation
1. Follow the removal procedure in reverse order. 2. Fill and leak check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure Hose
To Pump ..............................................................................................................................................
................................................. 40 Nm (30 ft. lbs.) To Gear ................................................................
................................................................................................................................. 20 Nm (15 ft.
lbs.)
Return Hose
To Gear ...............................................................................................................................................
.................................................. 20 Nm (15 ft. lbs.)
Routing Clip .........................................................................................................................................
................................................... 8 Nm (71 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications > Page 6232
Power Steering Line/Hose: Service and Repair
Removal
1. Refer to the illustration provided for the hose routing and retention points.
Installation
1. When connecting a fitting with a seal ring, a new seal ring must be installed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications > Page 6233
^ The special tool is used to install the return line connector seal and the pressure line connector
seal.
2. Fill and leak check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications > Page 6234
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Variable Assist Control Valve <-->
[Power Steering Pressure Control Valve] > Component Information > Specifications
Variable Assist Control Valve: Specifications
Power Steering Auxiliary Actuator
...........................................................................................................................................................
17 Nm (13 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications
Retaining Bolts ....................................................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications > Page 6242
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Flow [1] ................................................................................................................................................
............................................................. 3.0 ±0.2 gpm Capacity, Min [2] ..............................................
........................................................................................................................................................ 1.4
gpm Relief Pressure ............................................................................................................................
.................................................................... 1200-1380 psi
[1] Flow at 50 psi and 2500 rpm pump speed.
[2] At 750 psi.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 6243
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 6244
Power Steering Pump: Application and ID
CAUTION: Always use the ID code when ordering service parts.
The pump identification code is located on a tag attached to the power steering pump.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and Repair Power Steering Pump
With EVO Steering System
Removal
1. Remove the drive belt. 2. Raise the vehicle.
3. Remove the routing bracket.
4. Disconnect the power steering auxiliary actuator electrical connector. 5. Remove the pulley.
6. Disconnect the hose.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6247
7. Disconnect the hose.
8. Remove the four bolts and the power steering pump.
9. If the power steering pump is to be replaced, remove the power steering auxiliary actuator.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6248
1. Follow the removal procedure in reverse order.
^ Install new seal rings as necessary.
2. Fill and leak check the system.
Without EVO Steering System
Removal
1. Remove the drive belt. 2. Raise the vehicle.
3. Remove the routing bracket. 4. Remove the pulley.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6249
5. Disconnect the hose.
6. Disconnect the hose.
7. Remove the four bolts and the power steering pump.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6250
1. Follow the removal procedure in reverse order.
^ Install new seal rings as necessary.
2. Fill and leak check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6251
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Special Tools
Removal
1. Remove the drive belt. 2. Raise the vehicle.
3. CAUTION: Do not apply pressure on the power steering pump rotor shaft. Pressure will damage
internal thrust areas of the power
steering pump.
Use the special tool to remove the pulley. ^
Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks,
discard the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of
the pulley near the hub.
Installation
1. CAUTION: Replacement of the power steering pump pulley is necessary after being removed
and installed two times.
Use the special tool to install the power steering pump pulley. ^
Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks,
discard the pulley. If there is no paint or one paint
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6252
mark, use a paint pencil to mark the web area of the pulley near the hub.
2. Lower the vehicle. 3. Install the drive belt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Page 6253
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component
Information > Service and Repair
Power Steering Valve: Service and Repair
Removal
1. Raise the vehicle.
2. Remove the engine oil filter.
3. Disconnect the power steering auxiliary actuator electrical connector.
4. Remove the screw and the power steering auxiliary actuator.
Installation
1. Follow the removal procedure in reverse order. 2. Fill and check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Electronic Variable Orifice Steering
Module <--> [Steering Control Module] > Component Information > Locations
Electronic Variable Orifice Steering Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Electronic Variable Orifice Steering
Module <--> [Steering Control Module] > Component Information > Locations > Page 6260
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Electronic Variable Orifice Steering
Module <--> [Steering Control Module] > Component Information > Locations > Page 6261
Electronic Variable Orifice Steering Module: Service and Repair
Removal
1. Lower the panel.
2. Remove the lamp from the panel and disconnect the wiring.
3. Remove the screws.
4. Disconnect the wiring and remove the control module.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Electronic Variable
Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations
Electronic Variable Orifice Steering Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Electronic Variable
Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6266
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Electronic Variable
Orifice Steering Module <--> [Steering Control Module] > Component Information > Locations > Page 6267
Electronic Variable Orifice Steering Module: Service and Repair
Removal
1. Lower the panel.
2. Remove the lamp from the panel and disconnect the wiring.
3. Remove the screws.
4. Disconnect the wiring and remove the control module.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Specifications > Page 6272
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Specifications > Page 6273
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Specifications > Page 6274
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Specifications > Page 6278
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Specifications > Page 6279
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Specifications > Page 6280
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Arming and Disarming > Page 6287
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Warning Switch <--> [Key
Reminder Switch] > Component Information > Service and Repair
Key Warning Switch: Service and Repair
REMOVAL
1. Remove the ignition lock cylinder.
1 Insert the key into the ignition key and turn to the RUN position.
2 Insert a punch in the access hole of the steering column and press the release tab while pulling
out the ignition switch lock cylinder.
2. Remove the key-in-ignition warning switch.
1 Release the clip.
2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure
^ Verify ignition lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
Steering Gear: Specifications
GENERAL
Type .....................................................................................................................................................
............................. Recirculating Ball Torsion Bar Ratio ......................................................................
...................................................................................................................................................... 14:1
Input Turns (Lock to Lock) ...................................................................................................................
........................................................................ 3.4 Worm Bearing Preload, Max
.............................................................................................................................................................
0.9 Nm (8 inch lbs.) Total Meshload Over Worm
Bearing Preload (Over Ends)
............................................................................................................................................... 0.45-1
Nm (4-9 inch lbs.)
TIGHTENING SPECIFICATIONS
Ball Return Guide Clamp .....................................................................................................................
............................................... 6 Nm (53 inch lbs.) Fittings at Steering Gear ......................................
.................................................................................................................................. 20 Nm 15 ft.
lbs.) Power Steering Auxiliary Actuator
....................................................................................................................................................... 17
Nm (13 ft. lbs.) Retaining Bolts ............................................................................................................
......................................................................... 78 Nm (58 ft. lbs.) Sector Shaft Cover .......................
......................................................................................................................................................... 68
Nm (50 ft. lbs.) Valve Housing Bolts ....................................................................................................
......................................................................... 50 Nm (37 ft. lbs.) Steering Gear Race
Retaining Nut .......................................................................................................................................
........................................... 99 Nm (73 ft. lbs.) Race Setscrew ...........................................................
.................................................................................................................... 2 Nm (18 inch lbs.)
Meshload Adjuster Lock-Nut ...............................................................................................................
................................................ 31 Nm (23 ft. lbs.) Gear Meshload .....................................................
................................................................................................................. 1.4-1.8 Nm (12-16 inch
lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 6294
Steering Gear: Application and ID
CAUTION: Always use the ID code when ordering service parts.
The steering gear identification code is stamped into the housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments >
Meshload Check
Steering Gear: Adjustments Meshload Check
MESHLOAD
1. Rotate the input shaft either left or right to the stop. 2. Rotate the input shaft in the opposite
direction and count the number of turns. 3. Rotate the input shaft back one-half the number of turns
counted. 4. Using an inch-pound torque wrench, measure the torque required to rotate the input
shaft 45° either side of center.
5. If the torque exceeds specifications, adjust the meshload. Turn the sector shaft adjusting screw
to adjust the meshload.
6. CAUTION: Do not overtighten the lock nut or the threads in the sector shaft housing cover may
strip.
Tighten the meshload adjuster lock nut. 1
Hold the sector shaft adjusting screw.
2 Tighten the lock nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments >
Meshload Check > Page 6297
Steering Gear: Adjustments Meshload Adjustment
MESHLOAD ADJUSTMENT
1. NOTE: The engine should not be running.
Turn the steering wheel from right stop to left stop at least once.
2. Remove the driver side air bag. 3. Raise and support the vehicle.
4. Remove the steering sector shaft arm drag link nut.
5. Using the special tool, separate the steering sector shaft arm drag link.
6. NOTE: The front wheels should not touch the ground.
Lower and support the front of the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments >
Meshload Check > Page 6298
7. NOTE: Reset the steering gear meshload only if the measured rotating torque for total on-center
load is less than specification.
Attach a torque wrench to the (A) bolt and measure the steering gear meshload from center.
8. Meshload adjustment is necessary if out of specification.
9. Adjust the sector shaft to proper rotating torque.
1 Hold the sector shaft and loosen the meshload adjuster locknut.
2 Adjust the sector shaft.
10. Verify that the rotating torque is to specification.
^ Readjust if necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments >
Meshload Check > Page 6299
11. Tighten the meshload adjuster locknut.
1 Hold the sector shaft.
2 Tighten the locknut.
12. Install the steering sector shaft arm drag link nut.
1 Position the steering sector shaft arm drag link.
2 Install the steering sector shaft arm drag link nut.
13. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
14. Install the driver side air bag.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement
Steering Gear: Service and Repair Replacement
Removal
1. Separate and remove the cover.
2. Remove and discard the pinch bolt. 3. Make sure the ignition switch is in the locked position.
4. Separate the steering column lower shaft from the steering gear.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6302
5. Disconnect the lines. 6. Raise the vehicle.
7. Remove and discard the lock nut.
8. Using the special tool, separate the steering sector shaft arm drag link from the steering gear
sector shaft arm.
9. Remove the bolts and the steering gear.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6303
1. Follow the removal procedure in reverse order.
^ Install a new lock nut and pinch bolt.
^ Install new seal rings as necessary.
2. Fill and leak check the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6304
Steering Gear: Service and Repair Disassembly
NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear
replacement may be necessary.
1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on
the vise jaws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6305
2. Rotate the power steering gear input shaft and control from stop to stop and then center the
gear.
3. Remove the steering gear sector shaft housing cover bolts.
4. Tap on the lower end of the steering gear sector shaft.
5. Remove the steering gear sector shaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6306
6. Remove the locking nut from the steering gear sector shaft adjustment screw.
7. Remove the sector shaft housing cover.
^ Hold the steering gear sector shaft.
^ Turn the housing cover counterclockwise.
8. Remove the valve housing bolts and the identification tag.
9. Remove the valve housing and piston assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6307
10. Remove and discard the seal ring.
11. Remove the ball bearings.
1 Remove the bolts.
2 Remove the steering gear ball return guide clamp.
3 Remove the steering gear ball return guide.
4 Rotate the piston over a container to collect the 27-29 ball bearing.
12. Remove the input shaft valve and housing assembly from the piston.
13. Remove and discard the seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6308
14. Install the valve housing in the special tool and loosen the setscrew.
15. Using the special tool, remove the race nut.
16. Remove the power steering gear input shaft and control from the valve housing. 17. Rotate the
valve housing.
18. Pry the power steering gear input shaft seal out of the valve housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6309
19. Remove the input shaft snap ring.
20. Rotate the valve housing. Using the special tool, remove the bearing and power steering gear
input shaft seal. 21. Remove the valve housing from special tool 307-003 (T57L-500-B).
22. Install the steering gear housing in special tool 307-003 (T57L-500-B). Remove the steering
gear sector shaft dust seal from the sector shaft seal
bore.
23. Remove the spacer.
1 Remove the snap ring.
2 Remove the spacer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6310
24. NOTE: The steering gear sector shaft bearing is not replaceable.
Using the special tool, remove the sector shaft seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6311
Steering Gear: Service and Repair Assembly
1. Lubricate the sector shaft seal bore.
^ Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications
ESB-M1C93-B and ESR-M1C159-A.
2. Using the special tool, install the sector shaft seal.
^ Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent
meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
3. Install the spacer.
4. Install the snap ring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6312
5. NOTE: Place the steering gear sector shaft dust seal on the special tool so the raised lip is
toward the tool.
Using the special tool, install the sector shaft dust seal. ^
Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or
equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
^ Fill the space between the steering sector shaft dust seal and the sector shaft seal with
Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications
ESB-M1C93-Band ESR-M1C159-A.
6. Remove the steering gear housing from the special tool 307-003 (T57L-500-B).
7. Position the input shaft bearing in the valve housing. Using the special tool and a press, seat the
input shaft bearing.
8. Using the special tool, and a press, seat the power steering gear input shaft seal.
9. Install the input shaft snap ring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6313
10. Apply a liberal amount of Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford
specifications ESB-MlC93-B and ESR-M1C159-A
to the seal lip and the top surface of the power steering gear input shaft seal.
11. Using the special tool, install the power steering gear input shaft dust seal.
^ The dished or rubber side must face away from the valve housing.
12. Mount the valve housing in the special tool.
13. Install the power steering gear input shaft and control into the valve housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6314
14. Position the power steering gear race nut into the valve housing.
15. Using the special tool, tighten the race nut.
16. Install the setscrew.
17. Remove the valve housing from the special tool 307-003 (T57L-500-B). Position the piston on
the worm gear.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6315
18. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the
guides will result in a trapped ball or balls,
which could cause a vehicle accident. If the ball guides become unseated at any time, remove all
the balls and repeat the procedure.
Install the steering gear ball return guide on the piston.
19. WARNING: The correct number of balls are required for proper gear operation. Count the balls
and insert each carefully.
WARNING: To make sure the balls are correctly installed, rotate the steering gear input worm gear
and rack from one end of travel to the other without allowing the poppet adjuster to contact the
valve housing or moving the valve housing pilot face more than 69.1 mm (2-3/4 inches) from the
input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated,
reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that
cannot rotate, the steering gear will not function correctly and steering and gear failure can result.
Rotate the piston while holding the steering gear ball return guide and install the 27-29 ball
bearings into the opening in the ball guide.
20. Install the steering gear ball return guide clamp.
1 Position the steering gear ball return guide clamp.
2 Install the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6316
21. Install a new seal ring.
22. Lubricate and install the seal on the piston.
^ Use Multi-Purpose Grease DOAZ-19581AA or equivalent meeting Ford specifications
ESB-M1C93-B and ESR-M1C159-A.
23. Install the piston assembly into the steering gear housing. Make sure to align the oil passages
in the steering gear housing.
24. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6317
25. Loosely install the valve housing bolts and the identification tag, if so equipped.
26. Lubricate the O-ring on the sector shaft housing cover.
^ Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications
ESB-M1C93-B and ESR-M1C159-A.
27. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
28. Install the sector shaft lock nut. The sector shaft lock nut will be tightened during the steering
gear meshload adjustment.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Replacement > Page 6318
29. Install the sector shaft and housing assembly. Loosely install the sector shaft housing bolts.
30. Tighten the bolts.
31. Tighten the bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Page 6319
Steering Gear: Tools and Equipment
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
Steering Shaft: Specifications
Lower Steering Column Shaft Pinch Bolts
Lower ...................................................................................................................................................
........................................... 48 Nm (35 ft. lbs.) Upper .........................................................................
..................................................................................................................... 30 Nm (22 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
> Page 6323
Steering Shaft: Service and Repair
Removal
1. CAUTION: The steering column must be in the locked position, or the lower end of the steering
column is to be secured or wired in such
a way as to prevent the steering column from rotating, resulting in damage to the air bag sliding
contact.
Remove and discard the pinch bolt. Disconnect the upper half of the lower steering column shaft
from the steering column lower yoke.
2. Remove and discard the pinch bolt. Disconnect the lower steering column shafts from each
other.
3. Remove the upper half of the lower steering column shaft.
4. Remove the cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
> Page 6324
5. Remove and discard the pinch bolt.
6. Disconnect and remove the lower half of the lower steering column shaft from the steering gear.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
> Page 6325
1. Follow the removal procedure in reverse order.
^ Install new pinch bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications
Steering Wheel: Specifications
GENERAL
Free Play, Max. ...................................................................................................................................
..................................................... 6 mm (1/4-inch) Turning Effort, Static [1] .......................................
................................................................................................................................ 2.72 KG (6.0 lbs.)
Number of Turns [2] .............................................................................................................................
......................................................................... 3.4
TIGHTENING SPECIFICATION
Retaining Bolt [3] .................................................................................................................................
................................................. 40 Nm (30 ft. lbs.)
[1] Steering wheel turning effort. Engine running. Fluid at operating temperature.
[2] Lock to Lock.
[3] Use new steering wheel retaining bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications > Page 6329
Steering Wheel: Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped)
.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications > Page 6330
Steering Wheel: Service and Repair
Service Precautions
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle location of the front air bag sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Removal
1. NOTE: Make sure the wheels are in the straight-ahead position.
Disconnect the battery ground cable and wait at least one minute. ^
Disconnect the battery ground cable and wait at least one minute.
^ Disconnect the battery to starter relay cable.
2. Remove the driver side air bag module. 3. Disconnect the sliding contact electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications > Page 6331
4. Remove and discard the steering wheel bolt.
5. CAUTION: Removing the steering wheel without using a puller can damage the column
bearings.
Use the special tool to remove the steering wheel.
6. Remove the steering wheel while routing the wires from the air bag sliding contact through the
steering wheel.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications > Page 6332
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
Castellated Nuts ..................................................................................................................................
...................................................... 55 Nm (41 ft. lbs.) Adjusting Sleeve .............................................
.......................................................................................................................................... 28 Nm (21
ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner
Tie Rod End: Service and Repair Inner
Removal
1. Raise and support the vehicle.
2. NOTE: Both the left side and the right side inner tie-rod ends are removed the same way. Only
the left side is shown.
Remove the nut. 1
Remove the cotter pin.
2 Remove the nut.
3. Using the special tool, remove the tie-rod end from the steering sector shaft arm drag link.
4. NOTE: Count the number of threads on the old tie-rod end from the end of the shaft to the scribe
mark. This is the number of threads that the
tie-rod end should be installed into the front wheel spindle tie-rod adjusting sleeve.
Remove the inner tie-rod from the front wheel spindle tie-rod adjusting sleeve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner > Page 6339
1 Scribe a mark into the threads on the tie-rod end where shown.
2 Loosen the nut and bolt.
3 Remove the tie-rod end.
Installation
1. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front
wheel alignment has been checked.
NOTE: Both the left side and the right side inner tie-rod ends are installed the same way. Only the
left side is shown.
Install the tie-rod end into the front wheel spindle tie-rod adjusting sleeve.
2. Install the tie-rod end, nut and a new cotter pin. 3. Lower the vehicle. 4. Check the wheel
alignment. Adjust as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner > Page 6340
Tie Rod End: Service and Repair Outer
Removal
1. Raise and support the vehicle.
2. NOTE: Both the left side and the right side outer tie-rod ends are removed the same way. Only
the left side is shown.
Remove the nut. 1
Remove the cotter pin.
2 Remove the nut.
3. Using the special tool, remove the tie-rod end from the front wheel spindle.
4. NOTE: Count the number of threads on the old tie-rod end from the end of the shaft to the scribe
mark. This is the number of threads that the
tie-rod end should be installed into the front wheel spindle tie-rod adjusting sleeve.
Remove the outer tie-rod end from the front wheel spindle tie rod adjusting sleeve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner > Page 6341
1 Scribe a mark into the threads on the tie-rod end where shown.
2 Loosen the nut and bolt.
3 Remove the tie-rod end.
Installation
1. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front
wheel alignment has been checked.
NOTE: Both the left side and the right side outer tie-rod ends are installed the same way. Only the
left side is shown.
Install the tie-rod end into the front wheel spindle tie-rod adjusting sleeve.
2. Install the tie-rod end, nut and a new cotter pin. 3. Lower the vehicle. 4. Check the wheel
alignment. Adjust as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner > Page 6342
Tie Rod End: Service and Repair Replacement
Removal
1. Raise and support the vehicle.
2. NOTE: Both the left side and the right side outer tie-rod ends are removed the same way. Only
the left side is shown.
Remove the nut. 1
Remove the cotter pin.
2 Remove the nut.
3. Using the special tool, remove the tie-rod end from the front wheel spindle.
4. Remove the outer tie-rod from the front wheel spindle tie-rod adjusting sleeve.
1 Scribe a mark into the threads on the tie-rod end where shown.
2 Loosen the nut and bolt.
3 Remove the tie-rod end.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner > Page 6343
5. Remove the front wheel spindle tie-rod adjusting sleeve.
1 Scribe a mark into the threads on the front wheel spindle tie-rod adjusting sleeve where shown.
2 Loosen the nut and bolt.
3 Remove the front wheel spindle tie-rod adjusting sleeve.
Installation
1. NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front
wheel alignment has been checked.
NOTE: Install the front wheel spindle tie-rod adjusting sleeve until the scribe mark on the inner
tie-rod end and the front wheel spindle tie-rod adjusting sleeve meet.
Install the front wheel spindle tie-rod adjusting sleeve.
2. NOTE: Both the left side and the right side outer tie-rod ends are installed the same way. Only
the left side is shown.
NOTE: Install the outer tie-rod end into the front wheel spindle tie-rod adjusting sleeve until the
scribe mark on the outer tie-rod end and the front wheel spindle tie-rod adjusting sleeve meet.
NOTE: Do not tighten the clamp on the front wheel spindle tie-rod adjusting sleeve until the front
wheel alignment has been checked.
Install the tie-rod end into the front wheel spindle tie-rod adjusting sleeve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Inner > Page 6344
3. Install the tie-rod end, nut and a new cotter pin. 4. Lower the vehicle. 5. Check the wheel
alignment. Adjust as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Page 6345
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > NHTSA98V32200 > Jan > 99 > Recall 98V322000: Lower Ball Joint Cracking
Ball Joint: Recalls Recall 98V322000: Lower Ball Joint Cracking
NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT
CONTROL ARM: LOWER: BALL JOINT
Manufacturer: FORD MOTOR COMPANY
Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle
Potential Number of Units Affected: 158191
Summary:
Vehicle Description: Certain 1996-1999 Ford Crown Victoria police, fleet, natural gas, and
1996-1999 Lincoln Town Car limousine vehicles that were produced with a lower control arm ball
joint containing a one piece bearing; and 1990-1996 Ford Crown Victoria police, fleet, and NGV
vehicles and 1990-1996 Lincoln Town Car limousine vehicles that have been serviced with either a
ball joint containing the one-piece bearing or a front lower control arm containing ball joint with a
one-piece bearing. The one-piece bearing within the lower control arm ball joint can weaken slowly
during use and eventually crack. This could result in separation of the ball and cap of the joint,
allowing the control arm
to drop to the ground.
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk
of a crash.
Dealers will replace the lower control arm ball joints
(2). Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an
authorized dealer on an agreed upon service date and do not receive the the free remedy within a
reasonable time should contact Ford at 1-800-392-3673. Also contract the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > NHTSA98V322000 > Jan > 99 > Recall 98V322000: Lower Ball Joint Failure
Ball Joint: Recalls Recall 98V322000: Lower Ball Joint Failure
NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT
CONTROL ARM: LOWER: BALL JOINT
Manufacturer: FORD MOTOR COMPANY
Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle
Potential Number of Units Affected: 175000
Summary: Vehicle Description: On certain police, fleet, natural gas, and limousine vehicles, the
one-piece bearing within the lower control arm ball joint can weaken slowly during use and
eventually crack. This could result in separation of the ball and cap of the joint, allowing the control
arm to drop to the ground.
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk
of a crash.
Dealers will replace the lower control arm ball joints (2).
Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an
authorized dealer on an agreed upon service date and do not receive the free remedy within a
reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement
Technical Service Bulletin # 98S37 Date: 981201
Recall - Front Lower Control Arm Ball Joint Replacement
SAFETY RECALL 98337
Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford
Crown Victoria Police, Fleet, Taxi, Natural Gas Vehicles (NGV), and Lincoln Town Cars Equipped
with Limousine Package
^ Original - December, 1998
^ Important Recall Information
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Attachment III ^
Technical Information
^ Customer Notification Letter - 1995 And Forward Vehicles
^ Customer Notification Letter - 1994 And Prior Vehicles
^ Supplement # 1 - February, 1999
Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1993 through 1999 Ford
Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV), Lincoln Town Car Equipped with
Limousine Packages - Clarification of Lower Control Arm replacement as it relates to this recall.
^ Dealer Letter
^ Supplement # 2 - April, 1999
Announcing the Availability of Parts for 1994 and Prior Affected Vehicles
^ Dealer Letter
^ Attachment II ^
Labor Allowance
^ Parts Ordering Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6363
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6364
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6365
Attachment I - Administrative Information
DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company
records will be notified with the letter shown. If you have knowledge of an owner with an affected
vehicle that did not receive a notification letter, contact that owner, provide a copy of the letter as
shown and schedule a service appointment.
OASIS Use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE:
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT Affected vehicles on the enclosed list.
Other eligible vehicles which are brought to your dealership.
REGIONAL CONTACT Advise regional office if:
-- an owner cannot be contacted.
-- an owner does not make a service date.
CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing
is required, submit per ACES II Manual section 3-8.
REFUNDS See ACESII Manual, Section 3-63 for submission procedures.
For owner-paid front suspension lower control arm ball joint replacement made before the date of
the Owner Letter (or after the date of the letter if an emergency repair was made away from the
servicing dealer), enter using DWE;
Program Code - 98S37
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hrs.
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6366
LABOR ALLOWANCES
PARTS REQUIREMENTS
DEALER PRICE For latest prices, check or call your:
-- Order Processing Center
-- DOESII
-- Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
1995 Model Year and Foward Crown Victoria and Town Car
SERVICE PROCEDURE
The following service procedure will replace the left side lower ball joint. Repeat the procedure to
replace the right side lower ball joint.
1. Open hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6367
2. Disconnect front wheel ABS sensor electrical connector. See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well.
4. Raise and support vehicle.
5. Remove left front tire and wheel assembly.
6. Remove caliper anchor bracket retaining bolts. See Figure 2.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6368
Do not let caliper assembly hang from brake hose.
7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away
from steering knuckle.
8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly.
9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield.
10. Remove brake rotor dust shield.
11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle.
12. Remove cotter pin from tie-rod castle nut.
13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle.
14. Position jack stand under lower control arm.
15. Completely remove lower ball joint stud nut.
16. Reinstall lower ball joint stud nut a maximum of two (2) turns.
17. Remove jack stand supporting lower control arm.
18. Separate ball joint stud from steering knuckle.
19. Position jack stand under lower control arm.
20. Remove lower ball joint stud nut.
21. Using a block of wood for support, position steering knuckle away from lower control arm. See
Figure 3.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6369
22. Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool
T74P-4635-C on lower ball joint. See Figure 4.
NOTE:
Use only hand tools to press ball joint out of lower control arm.
23. Using installed tools and a breaker bar, press ball joint out of lower control arm.
24. Remove tools and ball joint from lower control arm.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6370
25. Install Ball Joint Replacer T8OT-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool
T74P-4635-C and new ball joint on lower control arm. See Figure 5.
NOTE:
Use only hand tools to press ball joint into lower control arm.
26. sing installed tools and a breaker bar, press ball joint into lower control arm.
27. Remove tools from lower control arm.
28. Reposition jack stand toward end of control arm.
29. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat
steering knuckle on ball joint stud.
30. Install ball joint stud nut. Tighten to 148-201 Nm (110-148 lb-ft).
31. Remove jack stand supporting lower control arm.
32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue
to tighten castle nut until slot for cotter pin is aligned.
33. Install new cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 26-35 Nm
(20-25 lb-ft).
35. Using rivets, install brake rotor dust shield.
36. Install brake rotor on hub.
37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting
bolts to 170-230 Nm (125-169 lb-ft).
38. Route the front wheel ABS sensor wiring into engine compartment.
39. Install left front tire and wheel assembly.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector.
42. Repeat procedure for right side lower ball joint.
43. With engine OFF, pump up brake system.
1994 Model Year and Prior Crown Victoria and Town Car
SERVICE PROCEDURE
The following service procedure will replace the left side lower ball joint. Repeat the procedure to
replace the right side lower ball joint.
1. Open hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6371
2. Disconnect front wheel ABS sensor electrical connector, if applicable.See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well, if applicable.
4. Raise and support vehicle.
5. Remove left front tire and wheel assembly.
6. Remove caliper anchor bracket retaining bolts. See Figure 2.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6372
Do not let caliper assembly hang from brake hose.
7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away
from steering knuckle.
8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly.
9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield.
10. Remove brake rotor dust shield.
11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering
knuckle.
12. Remove cotter pin from tie-rod castle nut.
13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle.
14. Position jack stand under lower control arm.
15. Remove cotter pin and loosen castle nut one (1) or two (2) turns.
16. Remove lack stand supporting lower control arm.
17. Separate ball joint stud from steering knuckle.
18. Position jack stand under lower control arm.
19. Remove lower ball joint stud castle nut.
20. Using a block of wood for support, position steering knuckle away from lower control arm. See
Figure 3.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6373
21. Install Ball Joint Remover D89P-301 0-A, Receiving Cup D84P-3395-A4 and U-Joint Tool
T74P-4635-C on lower ball joint. See Figure 4.
NOTE:
Use only hand tools to press ball joint out of lower control arm.
22. Using installed tools and a breaker bar, press ball joint out of lower control arm.
23. Remove tools and ball joint from lower control arm.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6374
24. Install Ball Joint Replacer T8OT-301O-A3, Receiving Cup D84P-3395-A4, U-Joint Tool
T74P-4635-C and new ball joint on lower control arm. See Figure 5.
NOTE:
Use only hand tools to press ball joint into lower control arm.
25. Using installed tools and a breaker bar, press ball joint into lower control arm.
26. Remove tools from lower control arm.
27. Reposition jack stand toward end of control arm.
28. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat
steering knuckle on ball joint stud.
29. Install ball joint stud castle nut. Tighten castle nut to 108-162 Nm (80-119 lb-ft). Continue to
tighten castle nut until slot for cotter pin is aligned.
30. Install new cotter pin in lower ball joint castle nut.
31. Remove jack stand supporting lower control arm.
32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue
to tighten castle nut until slot for cotter pin is aligned.
33. Install new Cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 40-55 Nm
(30-40 lb4t).
35. Using rivets, install brake rotor dust shield.
36. Install brake rotor on hub.
37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting
bolts to 170-230 Nm (125-169 lb-ft).
38. Route the front wheel ABS sensor wiring into engine compartment, if applicable.
39. Install left front tire and wheel assembly.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector, if applicable.
42. Repeat procedure for right side lower ball joint.
43. With engine OFF, pump up brake system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6375
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6376
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6377
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6378
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6379
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6380
Supplement # 2 - Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball Joint Replacement >
Page 6381
LABOR ALLOWANCES
DEALER PRICE For latest prices, check or call your:
-- Order Processing Center DOESII
-- Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA98V32200 > Jan > 99 > Recall 98V322000: Lower
Ball Joint Cracking
Ball Joint: All Technical Service Bulletins Recall 98V322000: Lower Ball Joint Cracking
NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT
CONTROL ARM: LOWER: BALL JOINT
Manufacturer: FORD MOTOR COMPANY
Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle
Potential Number of Units Affected: 158191
Summary:
Vehicle Description: Certain 1996-1999 Ford Crown Victoria police, fleet, natural gas, and
1996-1999 Lincoln Town Car limousine vehicles that were produced with a lower control arm ball
joint containing a one piece bearing; and 1990-1996 Ford Crown Victoria police, fleet, and NGV
vehicles and 1990-1996 Lincoln Town Car limousine vehicles that have been serviced with either a
ball joint containing the one-piece bearing or a front lower control arm containing ball joint with a
one-piece bearing. The one-piece bearing within the lower control arm ball joint can weaken slowly
during use and eventually crack. This could result in separation of the ball and cap of the joint,
allowing the control arm
to drop to the ground.
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk
of a crash.
Dealers will replace the lower control arm ball joints
(2). Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an
authorized dealer on an agreed upon service date and do not receive the the free remedy within a
reasonable time should contact Ford at 1-800-392-3673. Also contract the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA98V322000 > Jan > 99 > Recall 98V322000:
Lower Ball Joint Failure
Ball Joint: All Technical Service Bulletins Recall 98V322000: Lower Ball Joint Failure
NHTSA CAMPAIGN ID Number: 98V322000 Component: SUSPENSION: INDEPENDENT FRONT
CONTROL ARM: LOWER: BALL JOINT
Manufacturer: FORD MOTOR COMPANY
Year: 1999 Make: FORD Model: CROWN VICTORIA Year of Recall: '98 Type of Report: Vehicle
Potential Number of Units Affected: 175000
Summary: Vehicle Description: On certain police, fleet, natural gas, and limousine vehicles, the
one-piece bearing within the lower control arm ball joint can weaken slowly during use and
eventually crack. This could result in separation of the ball and cap of the joint, allowing the control
arm to drop to the ground.
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk
of a crash.
Dealers will replace the lower control arm ball joints (2).
Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an
authorized dealer on an agreed upon service date and do not receive the free remedy within a
reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement
Technical Service Bulletin # 98S37 Date: 981201
Recall - Front Lower Control Arm Ball Joint Replacement
SAFETY RECALL 98337
Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford
Crown Victoria Police, Fleet, Taxi, Natural Gas Vehicles (NGV), and Lincoln Town Cars Equipped
with Limousine Package
^ Original - December, 1998
^ Important Recall Information
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Attachment III ^
Technical Information
^ Customer Notification Letter - 1995 And Forward Vehicles
^ Customer Notification Letter - 1994 And Prior Vehicles
^ Supplement # 1 - February, 1999
Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1993 through 1999 Ford
Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV), Lincoln Town Car Equipped with
Limousine Packages - Clarification of Lower Control Arm replacement as it relates to this recall.
^ Dealer Letter
^ Supplement # 2 - April, 1999
Announcing the Availability of Parts for 1994 and Prior Affected Vehicles
^ Dealer Letter
^ Attachment II ^
Labor Allowance
^ Parts Ordering Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6395
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6396
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6397
Attachment I - Administrative Information
DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company
records will be notified with the letter shown. If you have knowledge of an owner with an affected
vehicle that did not receive a notification letter, contact that owner, provide a copy of the letter as
shown and schedule a service appointment.
OASIS Use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE:
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT Affected vehicles on the enclosed list.
Other eligible vehicles which are brought to your dealership.
REGIONAL CONTACT Advise regional office if:
-- an owner cannot be contacted.
-- an owner does not make a service date.
CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing
is required, submit per ACES II Manual section 3-8.
REFUNDS See ACESII Manual, Section 3-63 for submission procedures.
For owner-paid front suspension lower control arm ball joint replacement made before the date of
the Owner Letter (or after the date of the letter if an emergency repair was made away from the
servicing dealer), enter using DWE;
Program Code - 98S37
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hrs.
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6398
LABOR ALLOWANCES
PARTS REQUIREMENTS
DEALER PRICE For latest prices, check or call your:
-- Order Processing Center
-- DOESII
-- Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
1995 Model Year and Foward Crown Victoria and Town Car
SERVICE PROCEDURE
The following service procedure will replace the left side lower ball joint. Repeat the procedure to
replace the right side lower ball joint.
1. Open hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6399
2. Disconnect front wheel ABS sensor electrical connector. See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well.
4. Raise and support vehicle.
5. Remove left front tire and wheel assembly.
6. Remove caliper anchor bracket retaining bolts. See Figure 2.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6400
Do not let caliper assembly hang from brake hose.
7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away
from steering knuckle.
8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly.
9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield.
10. Remove brake rotor dust shield.
11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle.
12. Remove cotter pin from tie-rod castle nut.
13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle.
14. Position jack stand under lower control arm.
15. Completely remove lower ball joint stud nut.
16. Reinstall lower ball joint stud nut a maximum of two (2) turns.
17. Remove jack stand supporting lower control arm.
18. Separate ball joint stud from steering knuckle.
19. Position jack stand under lower control arm.
20. Remove lower ball joint stud nut.
21. Using a block of wood for support, position steering knuckle away from lower control arm. See
Figure 3.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6401
22. Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool
T74P-4635-C on lower ball joint. See Figure 4.
NOTE:
Use only hand tools to press ball joint out of lower control arm.
23. Using installed tools and a breaker bar, press ball joint out of lower control arm.
24. Remove tools and ball joint from lower control arm.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6402
25. Install Ball Joint Replacer T8OT-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool
T74P-4635-C and new ball joint on lower control arm. See Figure 5.
NOTE:
Use only hand tools to press ball joint into lower control arm.
26. sing installed tools and a breaker bar, press ball joint into lower control arm.
27. Remove tools from lower control arm.
28. Reposition jack stand toward end of control arm.
29. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat
steering knuckle on ball joint stud.
30. Install ball joint stud nut. Tighten to 148-201 Nm (110-148 lb-ft).
31. Remove jack stand supporting lower control arm.
32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue
to tighten castle nut until slot for cotter pin is aligned.
33. Install new cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 26-35 Nm
(20-25 lb-ft).
35. Using rivets, install brake rotor dust shield.
36. Install brake rotor on hub.
37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting
bolts to 170-230 Nm (125-169 lb-ft).
38. Route the front wheel ABS sensor wiring into engine compartment.
39. Install left front tire and wheel assembly.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector.
42. Repeat procedure for right side lower ball joint.
43. With engine OFF, pump up brake system.
1994 Model Year and Prior Crown Victoria and Town Car
SERVICE PROCEDURE
The following service procedure will replace the left side lower ball joint. Repeat the procedure to
replace the right side lower ball joint.
1. Open hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6403
2. Disconnect front wheel ABS sensor electrical connector, if applicable.See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well, if applicable.
4. Raise and support vehicle.
5. Remove left front tire and wheel assembly.
6. Remove caliper anchor bracket retaining bolts. See Figure 2.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6404
Do not let caliper assembly hang from brake hose.
7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away
from steering knuckle.
8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly.
9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield.
10. Remove brake rotor dust shield.
11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering
knuckle.
12. Remove cotter pin from tie-rod castle nut.
13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle.
14. Position jack stand under lower control arm.
15. Remove cotter pin and loosen castle nut one (1) or two (2) turns.
16. Remove lack stand supporting lower control arm.
17. Separate ball joint stud from steering knuckle.
18. Position jack stand under lower control arm.
19. Remove lower ball joint stud castle nut.
20. Using a block of wood for support, position steering knuckle away from lower control arm. See
Figure 3.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6405
21. Install Ball Joint Remover D89P-301 0-A, Receiving Cup D84P-3395-A4 and U-Joint Tool
T74P-4635-C on lower ball joint. See Figure 4.
NOTE:
Use only hand tools to press ball joint out of lower control arm.
22. Using installed tools and a breaker bar, press ball joint out of lower control arm.
23. Remove tools and ball joint from lower control arm.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6406
24. Install Ball Joint Replacer T8OT-301O-A3, Receiving Cup D84P-3395-A4, U-Joint Tool
T74P-4635-C and new ball joint on lower control arm. See Figure 5.
NOTE:
Use only hand tools to press ball joint into lower control arm.
25. Using installed tools and a breaker bar, press ball joint into lower control arm.
26. Remove tools from lower control arm.
27. Reposition jack stand toward end of control arm.
28. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat
steering knuckle on ball joint stud.
29. Install ball joint stud castle nut. Tighten castle nut to 108-162 Nm (80-119 lb-ft). Continue to
tighten castle nut until slot for cotter pin is aligned.
30. Install new cotter pin in lower ball joint castle nut.
31. Remove jack stand supporting lower control arm.
32. Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue
to tighten castle nut until slot for cotter pin is aligned.
33. Install new Cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 40-55 Nm
(30-40 lb4t).
35. Using rivets, install brake rotor dust shield.
36. Install brake rotor on hub.
37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting
bolts to 170-230 Nm (125-169 lb-ft).
38. Route the front wheel ABS sensor wiring into engine compartment, if applicable.
39. Install left front tire and wheel assembly.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector, if applicable.
42. Repeat procedure for right side lower ball joint.
43. With engine OFF, pump up brake system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6407
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6408
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6409
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6410
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6411
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6412
Supplement # 2 - Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control Arm Ball
Joint Replacement > Page 6413
LABOR ALLOWANCES
DEALER PRICE For latest prices, check or call your:
-- Order Processing Center DOESII
-- Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid
Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid
Front Lower Balljoint
Measurement
..................................................................................................................................................
Between lower control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.012 in (0-0.3mm)
Reference Diagram ...................................................... B - but a jackstand must be placed under
the lower control arm to "load the suspension".
Front Upper Balljoint
Measurement
..................................................................................................................................................
Between upper control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.008 in (0-0.2mm)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 6416
Reference Diagram ...................................................... C - but a jackstand must be placed under
the lower control arm to "load the suspension".
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 6417
Ball Joint: Specifications Ball Joint, Lower
GENERAL
Lateral Backlash, Max. ........................................................................................................................
.......................................... 1.0 mm (0.03937 inch) End Play, Max. ....................................................
.............................................................................................................................. 0.5 mm (0.020
inch)
TIGHTENING SPECIFICATIONS
Retaining Bolts
To Spindle ...........................................................................................................................................
....................................... 175 Nm (129 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 6418
Ball Joint: Specifications Ball Joint, Upper
GENERAL
Lateral Backlash, Max. ........................................................................................................................
.............................................. 0.4 mm (0.015 inch) End Play, Max. ....................................................
.............................................................................................................................. 0.5 mm (0.020
inch)
TIGHTENING SPECIFICATIONS
Retaining Bolts
To Upper Arm ......................................................................................................................................
...................................... 175 Nm (129 ft. lbs.) To Spindle ...................................................................
................................................................................................................... 90 Nm (66 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection
Ball Joint: Testing and Inspection Ball Joint Inspection
BALL JOINT INSPECTION-BACKLASH
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the luggage
compartment. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Inspect the ball joint boots for tears. If torn, install new ball joints as necessary. 3. Prior to
inspecting the ball joints for lateral backlash and end play, inspect the wheel bearings. 4. Using a
safety stand, support the front suspension lower arm to be inspected.
5. NOTE: Wheel and tire assembly removed for clarity.
While an assistant pushes and pulls equally on the top and bottom of the tire, observe any relative
lateral backlash between the front suspension upper arm and the front wheel spindle. If the lateral
backlash is at or exceeds the specification, a new ball joint must be installed.
6. NOTE: Wheel and tire assembly removed for clarity.
While an assistant moves the tire up and down, observe any relative end play between the front
suspension upper arm and the front wheel spindle. If the end play is at or exceeds the
specification, a new ball joint must be installed.
7. Remove the wheel and tire assembly. 8. Separate the front suspension lower arm from the front
wheel spindle.
^ Discard any fasteners that are removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 6421
9. Using the special tool, move the ball joint as shown and check for any lateral backlash. If the
lateral backlash is at, or exceeds, the specification, a
new ball joint must be installed.
10. Using the special tool, move the ball joint as shown and check for any end play. If the end play
is at, or exceeds, the specification, a new ball joint
must be installed.
11. Connect the front suspension lower arm to the front wheel spindle.
^ Install new fasteners.
12. Install the wheel and tire assembly. 13. Remove the safety stand. 14. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 6422
Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid
Front Lower Balljoint
Measurement
..................................................................................................................................................
Between lower control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.012 in (0-0.3mm)
Reference Diagram ...................................................... B - but a jackstand must be placed under
the lower control arm to "load the suspension".
Front Upper Balljoint
Measurement
..................................................................................................................................................
Between upper control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.008 in (0-0.2mm)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 6423
Reference Diagram ...................................................... C - but a jackstand must be placed under
the lower control arm to "load the suspension".
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint, Lower
Ball Joint: Service and Repair Ball Joint, Lower
Removal
1. Remove the front wheel spindle.
2. Remove and discard the ball joint dust boot.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint, Lower > Page 6426
3. Using the special tools, press the ball joint from the suspension lower arm.
Installation
1. NOTE: When installing a new front suspension lower ball joint, the protective cover must be left
in place during installation to protect the ball
joint seal. It may be necessary to cut off the end of the cover to allow it to pass through the
receiving cup.
Using the special tools, install the lower ball joint.
2. Discard the protective cover and check the front suspension lower ball joint to make sure it is
fully seated in the front suspension lower arm and
the ball joint seal is free of cuts or tears.
3. Install the spindle. 4. Check wheel alignment. Adjust as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint, Lower > Page 6427
Ball Joint: Service and Repair Ball Joint, Upper
Removal
1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Support the suspension
lower arm with a jack stand.
4. Remove the nut and pinch bolt. Discard the nut.
5. Mark the position of the alignment cams relative to the suspension upper arm for assembly
reference.
6. Remove the nuts, the alignment cams and the ball joint. Discard the nuts.
Installation
NOTE: Align the reference marks made during removal when installing the alignment cams.
NOTE: The nuts retaining the ball joint to the upper arm and the spindle are of a torque prevailing
design. New nuts must be installed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint, Lower > Page 6428
1. To install, reverse the removal procedure. 2. Check wheel alignment. Adjust as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Page 6429
Ball Joint: Tools and Equipment
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement
Technical Service Bulletin # 00B60 Date: 010201
Campaign - Rear Upper Control Arm Reinforcement
00B60 Owner Notification Program
All 1998 through 2000 Model Year Crown Victoria Police Interceptor, Taxi Cab, Natural Gas
Vehicles (NGV), and Lincoln Town Car Limousine Prep Package Vehicles - Rear Upper Control
Arm Bracket Reinforcement.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Owner Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6438
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6439
Attachment I - Administrative Information
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles brought to your
dealership.
DEALER-OWNER CONTACT
Promptly correct all affected vehicles on the enclosed list and other eligible vehicles brought to your
dealership. Immediately contact any affected owner whose name is not on the list. Give the owner
a copy of the Owner Letter and schedule a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter
(or after the date of the Owner Letter if an emergency repair was made away from the servicing
dealer). Refer to ACESII manual for refund information.
RENTAL CARS
Rental vehicle coverage is not included under this program.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6440
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels as noted.
DOR/COR NUMBER
DOR/COR Number 50213 identifies parts ordered for this campaign through the Recall Hotline
(1-800-325-5621).
DEALER PRICE
For latest prices, refer to
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SEVERE DUTY REAR FRAME REPAIR
AFFECTED VEHICLES: 1998 AND 2000 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR
(LIMOUSINE)
OVERVIEW
This procedure is for repairing cracks and installing reinforcement brackets on the rear control arm
mounts. Depending on the size of the cracks, some or all of the mounts will require coach welds.
All of the control arm mounts will have reinforcement brackets installed on them.
INSPECTION
NOTE:
All illustrations show the right side, the left side is similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6441
1. Record radio stations.
2. Disconnect the battery ground cable.
NOTE:
Upon reassembly, the control arms must be tightened with the vehicle suspension at ride height.
Therefore, the shock absorbers must be marked while the vehicle is still on the ground to show ride
height before the control arms are removed.
3. While parked on a level surface, mark the rear suspension shock absorbers relative to the
position of their protective sleeves.
4. Raise the vehicle on a hoist and remove the rear wheels.
NOTE:
Inspect both sides of the vehicle.
5. Clean and inspect the areas of the upper and lower control arm mounts for cracks as indicated in
the illustration. Measure the length of any cracks that are located. See Figure 1.
A. If any of the control arm mounts have separated from the frame rail, do not continue with this
procedure. Contact the recall hotline at 1-800-325-5621 for further instruction.
B. If no cracks are located, install reinforcement brackets on ALL control arm mounts. Perform
REINFORCEMENT BRACKET INSTALLATION.
C. Vehicles with only cracks of less than one-half inch in length, proceed as follows.
^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and
strategically placing coach welds on ONLY the control arm mount(s), which contain cracks.
^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on
ALL control arm mounts.
D. Vehicles with any cracks 1/2 inch long or greater, proceed as follows.
^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and placing
coach welds on ALL the control arm mounts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6442
^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on
ALL control arm mounts.
CRACK REPAIR AND COACH WELD PLACEMENT
NOTE:
Removal of control arm(s) (steps 3 or 4) is not necessary for mounts that do not require coach
welds.
1. Position safety stands under the rear axle housing.
2. If equipped with an air spring, wrap the air spring in a protective welding blanket.
3. Loosen the rear pivot bolt on the lower control arm, then remove the front pivot bolt. Rotate the
lower control arm downward, away from the frame mount.
4. Remove the upper control arm pivot bolts, then remove the upper control arm.
CAUTION
Grind only enough metal away to form the V-groove. Do not grind completely through the frame rail
or mount parent metal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6443
5. Grind a V-groove in all cracks, then remove the E-coat from around the cracks. Mig weld the
groove, using standard mig welding procedures. See Figures 2 and 3.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6444
6. Remove the E-coat from the frame rail(s) and control arm mounts(s) at the coach weld positions
as indicated in the illustrations. See Figures 4 and 5.
7. Place one (1) inch coach welds onto the frame rail(s)/control arm mount(s) (starting at the edge
of the mount) as indicated in the illustrations. See Figures 4 and 5.
REINFORCEMENT BRACKET INSTALLATION
NOTE:
If equipped with an air spring, wrap the air spring in a protective welding blanket (if not previously
installed during crack repair).
NOTE:
Reinforcement brackets MAY be welded onto mounts without removal of control arms.
CAUTION
Burn-through is not permitted. If any burn-through occurs, the hole must be filled.
CAUTION
Do not weld on the bends of the brackets.
CAUTION
Only remove E-coat and any weld material that interferes with reinforcement bracket fit. Do not
grind frame parent metal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6445
1. Prep the frame rail/upper control arm mount by removing the E-coat in the reinforcement bracket
mounting area. If necessary grind the weld on the front edge of the upper control arm mount. Grind
this weld only if it interferes with the reinforcement bracket sitting flush to the frame rail (bracket
must not rock). See Figure 6.
2. Position the upper control arm mount reinforcement bracket with the slotted hole closest to the
frame rail. The bracket must fit flush to the frame rail and must be centered vertically and flush with
the outer face of the upper control arm mount. Clamp the bracket into place. See Figure 6.
3. Tack weld the upper control arm mount reinforcement bracket into place. Remove the clamp(s).
Then finish weld the bracket following the sequence and direction as indicated in the illustration.
See Figure 7.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6446
4. Prep the frame rail/lower control arm mount by removing the E-coat in the reinforcement bracket
mounting area. See Figure 8.
5. Position the lower control arm mount reinforcement bracket. The bracket must fit flush to the
frame rail and flush with the outer face of the lower control arm mount. To begin, clamp the bracket
to the frame rail only. See Figure 8.
6. Tack weld the lower control arm mount reinforcement bracket to the frame rail. Then clamp and
tack weld the bracket to the lower control arm mount. Remove the clamp(s). Then finish weld the
bracket following the sequence and direction as indicated in the illustration. See Figure 9.
FINAL ASSEMBLY
1. Remove weld blankets, if previously installed.
2. Install all of the control arms and/or flag nut(s) that were removed. Do not final tighten at this
time.
3. Remove the safety stands.
WARNING
RIDE HEIGHT MUST BE ACHIEVED BY SUPPORTING THE REAR AXLE WITH SHORT
SAFETY STANDS WITH THE FRONT WHEELS ON THE FLOOR. ATTEMPTING TO POSITION
THE REAR AXLE TO RIDE HEIGHT WHILE THE VEHICLE IS STILL SUPPORTED BY THE
HOIST MAY RESULT IN SUDDEN SHIFTING OF THE VEHICLE ON THE HOIST AND
PERSONAL INJURY.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6447
4. Position two (2) short safety stands directly under the rear axle housing. Lower the hoist so the
rear axle is supported by the jack stands and the front wheels fully contact the floor.
5. Verify the rear shock absorber ride height reference marks are in alignment.
NOTE:
Tighten all of the control arms that were removed.
6. Tighten both lower control arm pivot bolts and the upper control arm to frame mount pivot bolt to
150 Nm (111 lb-ft). Tighten the upper control arm to axle bracket pivot bolt to 103 Nm (76 lb-ft).
7. Raise the vehicle on a hoist, then remove the safety stands.
8. Spray undercoating on reinforcement brackets, welds and all bare metal (avoid excessive
overspray).
9. Install the rear wheels. Tighten the lug nuts to 129 Nm (95 lb-ft).
10. Lower the vehicle, then connect the battery ground cable.
11. Program the radio stations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6448
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement >
Page 6449
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement
Technical Service Bulletin # 00B60 Date: 010201
Campaign - Rear Upper Control Arm Reinforcement
00B60 Owner Notification Program
All 1998 through 2000 Model Year Crown Victoria Police Interceptor, Taxi Cab, Natural Gas
Vehicles (NGV), and Lincoln Town Car Limousine Prep Package Vehicles - Rear Upper Control
Arm Bracket Reinforcement.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Owner Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6455
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6456
Attachment I - Administrative Information
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles brought to your
dealership.
DEALER-OWNER CONTACT
Promptly correct all affected vehicles on the enclosed list and other eligible vehicles brought to your
dealership. Immediately contact any affected owner whose name is not on the list. Give the owner
a copy of the Owner Letter and schedule a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter
(or after the date of the Owner Letter if an emergency repair was made away from the servicing
dealer). Refer to ACESII manual for refund information.
RENTAL CARS
Rental vehicle coverage is not included under this program.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6457
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing channels as noted.
DOR/COR NUMBER
DOR/COR Number 50213 identifies parts ordered for this campaign through the Recall Hotline
(1-800-325-5621).
DEALER PRICE
For latest prices, refer to
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SEVERE DUTY REAR FRAME REPAIR
AFFECTED VEHICLES: 1998 AND 2000 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR
(LIMOUSINE)
OVERVIEW
This procedure is for repairing cracks and installing reinforcement brackets on the rear control arm
mounts. Depending on the size of the cracks, some or all of the mounts will require coach welds.
All of the control arm mounts will have reinforcement brackets installed on them.
INSPECTION
NOTE:
All illustrations show the right side, the left side is similar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6458
1. Record radio stations.
2. Disconnect the battery ground cable.
NOTE:
Upon reassembly, the control arms must be tightened with the vehicle suspension at ride height.
Therefore, the shock absorbers must be marked while the vehicle is still on the ground to show ride
height before the control arms are removed.
3. While parked on a level surface, mark the rear suspension shock absorbers relative to the
position of their protective sleeves.
4. Raise the vehicle on a hoist and remove the rear wheels.
NOTE:
Inspect both sides of the vehicle.
5. Clean and inspect the areas of the upper and lower control arm mounts for cracks as indicated in
the illustration. Measure the length of any cracks that are located. See Figure 1.
A. If any of the control arm mounts have separated from the frame rail, do not continue with this
procedure. Contact the recall hotline at 1-800-325-5621 for further instruction.
B. If no cracks are located, install reinforcement brackets on ALL control arm mounts. Perform
REINFORCEMENT BRACKET INSTALLATION.
C. Vehicles with only cracks of less than one-half inch in length, proceed as follows.
^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and
strategically placing coach welds on ONLY the control arm mount(s), which contain cracks.
^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on
ALL control arm mounts.
D. Vehicles with any cracks 1/2 inch long or greater, proceed as follows.
^ Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and placing
coach welds on ALL the control arm mounts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6459
^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on
ALL control arm mounts.
CRACK REPAIR AND COACH WELD PLACEMENT
NOTE:
Removal of control arm(s) (steps 3 or 4) is not necessary for mounts that do not require coach
welds.
1. Position safety stands under the rear axle housing.
2. If equipped with an air spring, wrap the air spring in a protective welding blanket.
3. Loosen the rear pivot bolt on the lower control arm, then remove the front pivot bolt. Rotate the
lower control arm downward, away from the frame mount.
4. Remove the upper control arm pivot bolts, then remove the upper control arm.
CAUTION
Grind only enough metal away to form the V-groove. Do not grind completely through the frame rail
or mount parent metal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6460
5. Grind a V-groove in all cracks, then remove the E-coat from around the cracks. Mig weld the
groove, using standard mig welding procedures. See Figures 2 and 3.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6461
6. Remove the E-coat from the frame rail(s) and control arm mounts(s) at the coach weld positions
as indicated in the illustrations. See Figures 4 and 5.
7. Place one (1) inch coach welds onto the frame rail(s)/control arm mount(s) (starting at the edge
of the mount) as indicated in the illustrations. See Figures 4 and 5.
REINFORCEMENT BRACKET INSTALLATION
NOTE:
If equipped with an air spring, wrap the air spring in a protective welding blanket (if not previously
installed during crack repair).
NOTE:
Reinforcement brackets MAY be welded onto mounts without removal of control arms.
CAUTION
Burn-through is not permitted. If any burn-through occurs, the hole must be filled.
CAUTION
Do not weld on the bends of the brackets.
CAUTION
Only remove E-coat and any weld material that interferes with reinforcement bracket fit. Do not
grind frame parent metal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6462
1. Prep the frame rail/upper control arm mount by removing the E-coat in the reinforcement bracket
mounting area. If necessary grind the weld on the front edge of the upper control arm mount. Grind
this weld only if it interferes with the reinforcement bracket sitting flush to the frame rail (bracket
must not rock). See Figure 6.
2. Position the upper control arm mount reinforcement bracket with the slotted hole closest to the
frame rail. The bracket must fit flush to the frame rail and must be centered vertically and flush with
the outer face of the upper control arm mount. Clamp the bracket into place. See Figure 6.
3. Tack weld the upper control arm mount reinforcement bracket into place. Remove the clamp(s).
Then finish weld the bracket following the sequence and direction as indicated in the illustration.
See Figure 7.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6463
4. Prep the frame rail/lower control arm mount by removing the E-coat in the reinforcement bracket
mounting area. See Figure 8.
5. Position the lower control arm mount reinforcement bracket. The bracket must fit flush to the
frame rail and flush with the outer face of the lower control arm mount. To begin, clamp the bracket
to the frame rail only. See Figure 8.
6. Tack weld the lower control arm mount reinforcement bracket to the frame rail. Then clamp and
tack weld the bracket to the lower control arm mount. Remove the clamp(s). Then finish weld the
bracket following the sequence and direction as indicated in the illustration. See Figure 9.
FINAL ASSEMBLY
1. Remove weld blankets, if previously installed.
2. Install all of the control arms and/or flag nut(s) that were removed. Do not final tighten at this
time.
3. Remove the safety stands.
WARNING
RIDE HEIGHT MUST BE ACHIEVED BY SUPPORTING THE REAR AXLE WITH SHORT
SAFETY STANDS WITH THE FRONT WHEELS ON THE FLOOR. ATTEMPTING TO POSITION
THE REAR AXLE TO RIDE HEIGHT WHILE THE VEHICLE IS STILL SUPPORTED BY THE
HOIST MAY RESULT IN SUDDEN SHIFTING OF THE VEHICLE ON THE HOIST AND
PERSONAL INJURY.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6464
4. Position two (2) short safety stands directly under the rear axle housing. Lower the hoist so the
rear axle is supported by the jack stands and the front wheels fully contact the floor.
5. Verify the rear shock absorber ride height reference marks are in alignment.
NOTE:
Tighten all of the control arms that were removed.
6. Tighten both lower control arm pivot bolts and the upper control arm to frame mount pivot bolt to
150 Nm (111 lb-ft). Tighten the upper control arm to axle bracket pivot bolt to 103 Nm (76 lb-ft).
7. Raise the vehicle on a hoist, then remove the safety stands.
8. Spray undercoating on reinforcement brackets, welds and all bare metal (avoid excessive
overspray).
9. Install the rear wheels. Tighten the lug nuts to 129 Nm (95 lb-ft).
10. Lower the vehicle, then connect the battery ground cable.
11. Program the radio stations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6465
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper Control
Arm Reinforcement > Page 6466
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical
Service Bulletins > Page 6467
Control Arm: Specifications
RETAINING BOLTS/NUTS
Front
Upper Arm to Frame.............................................................................................................................
....................................... 175 Nm (129 ft. lbs.) Lower Arm to Frame ..................................................
................................................................................................................ 175 Nm (129 ft. lbs.)
Rear
Lower Arm
Front and Rear ....................................................................................................................................
.................................. 150 Nm (111 ft. lbs.)
Upper Arm
Front (Frame) ......................................................................................................................................
.................................. 150 Nm (111 ft. lbs.) Rear (Axle) ......................................................................
....................................................................................................... 103 Nm (76 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front
Control Arm: Service and Repair Front
Lower
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. They must be
replaced with the same part number or an equivalent part if replacement is necessary. Do not use
a replacement part of lesser quality of substitute design. Torque values must be used during
reassembly to ensure proper retention of these parts.
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.
3. Remove the cotter pin and nut. Discard the cotter pin.
4. Using the special tool, remove the tie-rod end from the front wheel spindle. 5. Remove the coil
spring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6470
6. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be
installed whenever the nut is loosened or
removed.
Remove and discard the nut.
7. Using the special tool, remove the front suspension lower arm.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6471
1. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be
installed whenever the nut is loosened or
removed.
NOTE: Do not tighten the front suspension lower arm bolts until the vehicle's suspension is at curb
height.
To install, reverse the removal procedure.
Upper
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. They must be
replaced with the same part number or an equivalent part if replacement is necessary. Do not use
a replacement part of lesser quality or substitute design. Torque values must be used during
reassembly to ensure proper retention of these parts.
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Place a suitable jack
stand under the front suspension lower arm and lower the vehicle until the lower arm begins to
move. 4. Attach a piece of safety wire to the front wheel spindle and secure the spindle to the
frame.
5. Remove the bolt and nut.
6. Remove the front suspension upper arm.
1 Remove the two nuts and bolts.
2 Remove the front suspension upper arm.
Installation
1. NOTE: Do not tighten the front suspension upper arm nuts and bolts until the vehicle's
suspension is at curb height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6472
To install, reverse the removal procedure.
2. Check wheel alignment. Adjust if necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6473
Control Arm: Service and Repair Rear
With Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, Jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off.
2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a
static, level ground position (curb height). 3. Raise and support the vehicle. 4. Remove the wheel
and tire assembly. 5. Use the special tool 014-0094 or equivalent to support the rear axle.
6. WARNING: Do not remove an air spring under any circumstances when there is air pressure in
the air spring. Do not remove any
components supporting an air spring without exhausting the air.
Release the air pressure from the air springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6474
7. Remove and discard the rear suspension lower arm pivot bolt and nut from the axle bracket.
8. Remove and discard the rear suspension lower arm pivot bolt and nut from the frame bracket.
Remove the rear suspension lower arm.
Installation
1. NOTE: The rear suspension lower arm bolts must be tightened with the vehicle at curb height.
NOTE: The rear suspension lower arms are interchangeable from side-to-side with "OUTBOARD"
stamped on the side of the arm for positioning during installation.
Position the rear suspension lower arm to the frame bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces inboard. Do not tighten at this time.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6475
2. Position the rear suspension lower arm to the axle bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces outboard. Do not
tighten at this time.
3. Raise the axle assembly to the position that compresses the shock absorber to the previously
established alignment mark (curb height).
4. Tighten the rear suspension lower arm to the frame bracket pivot bolt.
5. Tighten the rear suspension lower arm to axle bracket pivot bolt. 6. Remove the special tool
014-0094 or equivalent. 7. Lower the vehicle.
8. Turn the air suspension service switch on. 9. Inflate the air springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6476
Without Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a
static, level ground position (curb height). 2. Raise and support the vehicle. 3. Remove the wheel
and tire assembly. 4. Use the special tool 014-0094 or equivalent to support the rear axle.
5. Remove and discard the rear suspension lower arm pivot bolt and nut from the axle bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6477
6. Remove and discard the rear suspension lower arm pivot bolt and nut from the frame bracket.
Remove the rear suspension lower arm.
Installation
1. NOTE: The rear suspension lower arm bolts must be tightened with the vehicle at curb height.
NOTE: The rear suspension lower arms are interchangeable from side-to-side with "OUTBOARD"
stamped on the side of the arm for positioning during installation.
Position the rear suspension lower arm to the frame bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces inboard. Do not tighten at this time.
2. Position the rear suspension lower arm to the axle bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces outboard. Do not
tighten at this time.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6478
3. Raise the axle assembly to the position that compresses the shock absorber to the previously
established alignment mark (curb height).
4. Tighten the rear suspension lower arm to the frame bracket pivot bolt.
5. Tighten the rear suspension lower arm to axle bracket pivot bolt. 6. Remove the special tool
014-0094 or equivalent. 7. Lower the vehicle.
With Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6479
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off.
2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a
static, level ground position (curb height). 3. Raise and support the vehicle. 4. Use the special tool
014-0094 or equivalent to support the rear axle.
5. WARNING: Do not remove an air spring under any circumstances when there is air pressure in
the air spring. Do not remove any
components supporting an air spring without exhausting the air.
Release the air pressure from the air springs.
6. CAUTION: Do not use excessive force when removing the pivot bolt and flag nut on the right
upper suspension arm to axle bracket.
Damage to the brake line can occur.
Remove and discard the rear suspension upper arm pivot bolt and nut from the axle bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6480
7. Remove and discard the rear suspension upper arm pivot bolt and nut from the frame bracket.
Remove the rear suspension upper arm.
Installation
1. NOTE: The rear suspension upper arm bolts must be tightened with the vehicle at curb height.
NOTE: The rear suspension upper arms are interchangeable from side-to-side with "FRONT" and
"OUTBOARD" stamped on the side of the arms for positioning during installation.
Position the rear suspension upper arm to the frame bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces inboard. Do not tighten at this time.
2. Position the rear suspension upper arm to the axle bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces outboard. Do not
tighten at this time.
3. Raise the axle assembly to the position that compresses the shock absorber to the previously
established alignment mark (curb height).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6481
4. Tighten the bolt.
5. Tighten the bolt. 6. Remove the special tool 01-0094 or equivalent. 7. Lower the vehicle.
8. Turn the air suspension service switch on. 9. Inflate the air springs.
Without Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6482
parts.
1. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a
static, level ground position (curb height). 2. Raise and support the vehicle. 3. Use the special tool
014-0094 or equivalent to support the rear axle.
4. CAUTION: Do not use excessive force when removing the pivot bolt and flag nut on the right
upper suspension arm to axle bracket.
Damage to the brake line can occur.
Remove and discard the rear suspension upper arm pivot bolt and nut from the axle bracket.
5. Remove and discard the rear suspension upper arm pivot bolt and nut from the frame bracket.
Remove the rear suspension upper arm.
Installation
1. NOTE: The rear suspension upper arm bolts must be tightened with the vehicle at curb height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6483
NOTE: The rear suspension upper arms are interchangeable from side-to-side with "FRONT" and
"OUTBOARD" stamped on the side of the arms for positioning during installation.
Position the rear suspension upper arm to the frame bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces inboard. Do not tighten at this time.
2. Position the rear suspension upper arm to the axle bracket and install a new pivot bolt and nut.
Insert the bolt so the nut faces outboard. Do not
tighten at this time.
3. Raise the axle assembly to the position that compresses the shock absorber to the previously
established alignment mark (curb height).
4. Tighten the bolt.
5. Tighten the bolt. 6. Remove the special tool 01-0094 or equivalent.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6484
7. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Page 6485
Control Arm: Tools and Equipment
Rear Suspension
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Specifications
Lateral Stabilizer Rod: Specifications
NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened
with the vehicle at curb height.
Watts Link
Pivot Stud ............................................................................................................................................
............................................. 270 Nm (199 ft. lbs.) Pivot Nut ..............................................................
............................................................................................................................. 250 Nm (184 ft.
lbs.)
Lateral Arm
Arms To Watts Link .............................................................................................................................
................................................ 92 Nm (68 ft. lbs.) Arms To Frame Brackets ......................................
.............................................................................................................................. 103 Nm (76 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly
Lateral Stabilizer Rod: Service and Repair Disassembly and Assembly
With Air Suspension
Disassembly
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Remove the lateral arm and Watts link pivot assembly.
2. Mark the position of the lateral arms on the Watts link pivot for positioning during installation.
3. Mark the position of the height sensor mounting bracket to the lateral arm for positioning during
installation.
4. Remove the height sensor mounting bracket retaining nuts and remove the bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6491
5. Remove the lateral arm retaining nuts from the Watts link pivot and remove the arms.
Assembly
1. CAUTION: If installing a new Watts link pivot or lateral arms, mark the new part in the same
place the old part was marked during
disassembly. Make sure the marks are lined up correctly during assembly. Failure to do so can
cause premature wear of the bushings or, on a vehicle equipped with air suspension, incorrect ride
height, resulting in poor ride and handling.
CAUTION: If installing a new Watts link pivot, make sure it is facing the right direction. "FRONT" is
stamped on the Watts link pivot. Failure to do so will result in damage to the Watts link.
Follow the disassembly procedure in reverse order.
Without Air Suspension
Disassembly
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Remove the lateral arm and Watts link pivot assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6492
2. Mark the position of the lateral arms on the Watts link pivot for positioning during installation.
3. Remove the lateral arm retaining nuts from the Watts link pivot and remove the arms.
Assembly
1. CAUTION: If installing a new Watts link pivot or lateral arms, mark the new part in the same
place the old part was marked during
disassembly. Make sure the marks are lined up correctly during assembly. Failure to do so can
cause premature wear of the bushings or, on a vehicle equipped with air suspension, incorrect ride
height, resulting in poor ride and handling.
CAUTION: If installing a new Watts link pivot, make sure it is facing the right direction. "FRONT" is
stamped on the Watts link pivot. Failure to do so will result in damage to the Watts link.
Follow the disassembly procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6493
Lateral Stabilizer Rod: Service and Repair Replacement
With Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off.
2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a
static, level ground position (curb height). 3. Raise and support the vehicle. 4. Use the special tool
014-0094 or equivalent to support the rear axle.
5. WARNING: Do not remove an air spring under any circumstances when there is air pressure in
the air spring. Do not remove any
components supporting an air spring without exhausting the air.
Release the air pressure from the air springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6494
6. Disconnect the height sensor from the mounting bracket.
7. Remove and discard both lateral arm assembly pivot bolts and nuts.
8. NOTE: The Watts link pivot stud is coated with a dry adhesive and must be replaced whenever
the pivot nut or stud is loosened or removed with
a new Watts link pivot nut and stud service kit.
NOTE: If the Watts link pivot stud on the axle assembly loosens while removing the pivot nut,
continue to loosen the pivot stud until you can insert an open end wrench to hold the pivot stud.
While holding the pivot stud, remove the pivot nut.
Remove and discard the Watts link pivot nut.
9. Lower the axle until the Watts link is free of the pivot stud. Remove the lateral arm assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6495
10. Remove and discard the Watts link pivot stud.
Installation
1. Install a new Watts link pivot stud.
2. NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened
with the vehicle at curb height.
Install the lateral arm assembly on the pivot stud making sure the flange of the right arm faces the
front of the vehicle.
3. Raise the axle until the lateral arm assembly aligns with the frame brackets and install new pivot
bolts and nuts. Do not tighten at this time.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6496
4. Raise the axle assembly to the position that compresses the shock absorber to the previously
established alignment mark (curb height).
5. Tighten both bolts.
6. Tighten the nut.
7. Connect the height sensor to the mounting bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6497
8. Remove the special tool 014-0094 or equivalent. 9. Lower the vehicle.
10. Turn the air suspension service switch on. 11. Inflate the air springs.
Without Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a
static, level ground position (curb height). 2. Raise and support the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6498
3. Use the special tool 014-0094 or equivalent to support the rear axle.
4. Remove and discard both lateral arm assembly pivot bolts and nuts.
5. NOTE: The Watts link pivot stud is coated with a dry adhesive and must be replaced whenever
the pivot nut or stud is loosened or removed with
a new Watts link pivot nut and stud service kit.
NOTE: If the Watts link pivot stud on the axle assembly loosens while removing the pivot nut,
continue to loosen the pivot stud until you can insert an open end wrench to hold the pivot stud.
While holding the pivot stud, remove the pivot nut.
Remove and discard the Watts link pivot nut.
6. Lower the axle until the Watts link is free of the pivot stud. Remove the lateral arm assembly.
7. Remove and discard the Watts link pivot stud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6499
Installation
1. Install a new Watts link pivot stud.
2. NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened
with the vehicle at curb height.
Install the lateral arm assembly on the pivot stud making sure the flange of the right arm faces the
front of the vehicle.
3. Raise the axle until the lateral arm assembly aligns with the frame brackets and install new pivot
bolts and nuts. Do not tighten at this time.
4. Raise the axle assembly to the position that compresses the shock absorber to the previously
established alignment mark (curb height).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Disassembly and Assembly > Page 6500
5. Tighten both bolts.
6. Tighten the nut.
7. Remove the special tool 014-0094 or equivalent. 8. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Page 6501
Special Tool
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6506
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6507
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Retaining Screws .................................................................................................................................
..................................... 2.3-3.3 Nm (20-29 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 6511
Suspension Control Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 6512
Suspension Control Module: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 6513
Suspension Control Module: Description and Operation
A microprocessor controls the air suspension system. The microprocessor and its supporting
hardware are contained in the air suspension control module. The air suspension control module
responds to signals from various sensors in the vehicle to maintain the programmed ride height
while the vehicle is either moving or stopped. The air suspension control module accomplishes this
by opening and closing solenoid valves to control the amount of air in the air spring(s). The air
suspension control module turns on the compressor by applying voltage through the compressor
relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the
vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs
from the air suspension height sensor(s).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 6514
Suspension Control Module: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Pull out the lower instrument panel insulator.
1 Remove the pushpins.
2 Pull out the lower instrument panel insulator.
4. Remove the lower instrument panel insulator.
1 Disconnect the power point.
2 Disconnect the courtesy lamp.
3 Remove the lower instrument panel insulator.
5. Remove the rear air suspension control module.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the rear air suspension control module.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 6515
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Specifications
Ride Height Sensor: Specifications
Mounting Bracket To Lateral Arm
...........................................................................................................................................................
14 Nm (10 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Specifications > Page 6520
Ride Height Sensor: Description and Operation
The air suspension height sensor sends signals to the air suspension control module. There are
three possible conditions that the air suspension control module interprets from the signals of the
air suspension height sensors. The conditions are trim height, below trim height, or above trim
height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Specifications > Page 6521
Ride Height Sensor: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support
the vehicle.
4. Disconnect the air suspension height sensor electrical connector.
5. Remove the air suspension height sensor.
^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball
studs.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Specifications
Steering Angle Sensor: Specifications
Shock Absorber Electronic
Steering Sensor Screws ......................................................................................................................
............................................. 1 Nm (9 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Specifications > Page 6525
Steering Angle Sensor: Description and Operation
The steering sensor provides the steering rate and position to the air suspension control module to
avoid overcompensation of the air suspension during turns.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Specifications > Page 6526
Steering Angle Sensor: Service and Repair
Removal
1. Remove the screws.
2. Remove the sound panel.
3. Remove the finish panel.
4. Remove the knee bolster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Specifications > Page 6527
5. Remove the bracket.
6. Remove the sensor.
1 Disconnect the wiring.
2 Remove the screws.
3 Remove the sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension
Mode Switch > Component Information > Description and Operation
Suspension Mode Switch: Description and Operation
CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is
hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of
the system and possible damage to the air suspension system components.
The air suspension switch provides a signal to the air suspension control module in the ON position
to activate the system to maintain the programmed vehicle height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension
Mode Switch > Component Information > Description and Operation > Page 6531
Suspension Mode Switch: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Peel back the luggage compartment trim.
1 Remove the pushpins.
2 Peel back the luggage compartment trim.
4. Remove the air suspension switch.
1 From behind the quarter panel reinforcement, depress the clips.
2 Remove the air suspension switch.
5. Disconnect the electrical connector.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair
Spindle: Service and Repair
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. They must be
replaced with the same part number or an equivalent part if replacement is necessary. Do not use
a replacement part of lesser quality or substitute design. Torque values must be used during
reassembly to ensure proper retention of these parts.
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. Remove the cotter pin and nut. Discard the cotter pin.
5. Using the special tool, disconnect the tie-rod end from the front wheel spindle.
6. CAUTION: Do not remove the lower ball joint nut at this time. The nut will retain the lower ball
joint into the wheel spindle, preventing
the spring from flying out and causing personal injury or damage to the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair > Page 6535
Disconnect the lower ball joint from the front wheel spindle. 1
Loosen the nut, leaving at least three threads engaged in the ball joint.
2 Using a hammer, sharply rap on the front wheel spindle until the lower ball joint disconnects from
the spindle.
7. Place a suitable jack stand under the front suspension lower arm. Lower the vehicle until the
front suspension lower arm begins to move.
8. Remove the ABS sensor.
1 Remove the bolt.
2 Remove the ABS sensor.
9. Remove the stabilizer bar link from the front wheel spindle.
1 Remove the nut.
2 Remove the link.
10. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be
installed whenever the nut is loosened or
removed.
Remove the lower ball joint nut. Discard the nut.
11. Remove the front wheel spindle.
1 Remove the pinch bolt and nut.
2 Raise the front suspension upper arm.
3 Remove the front wheel spindle.
12. NOTE: If a new front wheel spindle is to be installed, the wheel hub and bearing and the brake
disc shield will have to be removed from the
spindle.
Remove the wheel hub and bearing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair > Page 6536
13. Remove the front brake disc shield.
1 Using a 3/16 drill bit, remove the rivets.
2 Remove the brake disc shield.
Installation
1. NOTE: If the front brake disc shield and the wheel hub and bearing were removed, they will have
to be installed.
Install the front brake disc shield. 1
Position the front brake disc shield.
2 Install the rivets.
2. Install the wheel hub and bearing.
3. NOTE: The lower control arm ball joint nut is coated with a dry adhesive and a new nut must be
installed whenever the nut is loosened or
removed.
Install the front wheel spindle. 1
Position the front wheel spindle onto the lower ball joint.
2 Install the new nut finger tight.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair > Page 6537
4. Connect the upper arm to the spindle.
1 Position the upper ball joint into the front wheel spindle.
2 Install the pinch bolt and nut.
5. Tighten the nut.
6. Install the stabilizer bar link.
1 Position the stabilizer bar link.
2 Install the nut.
7. Remove the jack stand.
8. Install the tie-rod end.
1 Position the tie-rod end.
2 Install the nut.
3 Install a new cotter pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair > Page 6538
9. Install the ABS sensor.
1 Position the ABS sensor.
2 Install the bolt.
10. Install the front brake disc. 11. Install the wheel and tire assembly. 12. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair > Page 6539
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Service and Repair
Stabilizer Bushing: Service and Repair
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. They must be
replaced with the same part number or an equivalent part if replacement is necessary. Do not use
a replacement part of lesser quality or substitute design. Torque values must be used during
reassembly to ensure proper retention of these parts.
1. Raise and support the vehicle.
2. NOTE: Both the left side and the right side stabilizer bar bushings are removed the same way.
Only the right side is shown.
Remove the stabilizer bar bracket. 1
Remove the nuts.
2 Remove the bracket.
3. Remove the stabilizer bar bushing.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Specifications
Stabilizer Link: Specifications
Retaining Nuts
Front
To Spindle ...........................................................................................................................................
........................................... 30 Nm (22 ft. lbs.) To Bar ........................................................................
..................................................................................................................... 55 Nm (41 ft. lbs.)
Rear
To Frame .............................................................................................................................................
........................................... 20 Nm (15 ft. lbs.) To Bar ........................................................................
..................................................................................................................... 20 Nm (15 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front
Stabilizer Link: Service and Repair Front
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. They must be
replaced with the same part number or an equivalent part if replacement is necessary. Do not use
a replacement part of lesser quality or substitute design. Torque values must be used during
reassembly to ensure proper retention of these parts.
1. Raise and support the vehicle. 2. Remove the front wheel and tire assemblies.
3. NOTE: Both the left side and the right side stabilizer bar link are removed the same way. Only
the right side is shown.
Disconnect the front stabilizer bar. 1
Remove the nut.
2 Disconnect the front stabilizer bar.
4. Remove the stabilizer bar link.
1 Remove the nut.
2 Remove the stabilizer bar link.
Installation
1. NOTE: Both the left side and the right side stabilizer bar link are installed the same way. Only
the right side is shown.
Install the stabilizer bar link.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6549
1 Position the stabilizer bar link.
2 Install the nut.
2. Connect the front stabilizer bar.
1 Position the front stabilizer bar.
2 Install the nut.
3. Install the front wheel and tire assemblies. 4. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6550
Stabilizer Link: Service and Repair Rear
With Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off.
2. Raise and support the vehicle. 3. Use the special tool 014-0094 or equivalent to support the rear
axle.
4. WARNING: Do not remove an air spring under any circumstances when there is air pressure in
the air spring. Do not remove any
components supporting an air spring without exhausting the air.
Release the air pressure from the air springs.
5. Remove both stabilizer bar link lower retaining nuts and bushings.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6551
6. Remove both stabilizer bar link upper retaining nuts and bushings. Remove the links.
7. Remove both stabilizer bar mounting bracket bolts. Remove the brackets and the stabilizer bar.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6552
2. Inflate the air springs.
Without Air Suspension
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Raise and support the vehicle. 2. Use the special tool 014-0094 or equivalent to support the rear
axle.
3. Remove both stabilizer bar link lower retaining nuts and bushings.
4. Remove both stabilizer bar link upper retaining nuts and bushings. Remove the links.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6553
5. Remove both stabilizer bar mounting bracket bolts. Remove the brackets and the stabilizer bar.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Dryer, Suspension Control > Component Information > Specifications
Air Dryer: Specifications
Retaining Bolts ....................................................................................................................................
........................................... 2-3 Nm (18-27 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Dryer, Suspension Control > Component Information > Specifications > Page 6558
Air Dryer: Service and Repair
Removal
1. Remove the air compressor.
2. Remove the air compressor drier.
1 Remove the screw.
2 Rotate 90° to unlock then remove the air compressor drier.
Installation
1. NOTE: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal
area with Silicone Brake Caliper Grease and
Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A.
NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Line, Suspension Control > Component Information > Service and Repair
Air Line: Service and Repair
NOTE: A soapy water solution can be applied to the air lines to verify the location of air leaks.
1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight
cut. Trim back the outer covering of the air line
16-20 mm (0.63-0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely
with electrical tape.
2. If multiple leaks are detected, replace the entire air line.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Locations > Page 6565
Air Spring: Description and Operation
WARNING: Never rotate an air spring solenoid valve to the release slot in the air spring end cap
fitting until all pressurized air has escaped from the air spring to prevent vehicle damage or
personal injury.
The air spring solenoid valve allows air to enter and exit the rear air springs during height
adjustment operations. The air spring solenoid valve is electrically operated and controlled by the
air suspension control module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Service and Repair > Air Spring Filling or Refolding
Air Spring: Service and Repair Air Spring Filling or Refolding
AIR SPRING FILL - REFOLD
WARNING: Do not remove an air spring under any circumstances when there is pressure in the air
spring. Do not remove any components supporting an air spring without either exhausting the air or
providing support for the air spring to prevent vehicle damage or personal injury.
CAUTION: Do not clamp any portion of the air spring piston.
1. Place air spring on flat surface.
2. Remove air spring solenoid to expand collapsed air bag.
3. Push membrane down over piston to correct height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6568
4. Install air spring solenoid to help maintain correct height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6569
Air Spring: Service and Repair Replacement
Removal
WARNING: Do not remove an air spring under any circumstances when there is pressure in the air
spring. Do not remove any components supporting an air spring without either exhausting the air or
providing support for the air spring to prevent vehicle damage or personal injury.
WARNING: Disconnecting an air line that is connected to the air compressor can cause personal
injury or damage to components as high pressure air is vented uncontrolled.
1. WARNING:
^ Do not attempt to install or inflate any rear air spring that has become unfolded to prevent vehicle
damage or personal injury.
^ Failure to observe the procedures may result in a sudden failure of the air spring or suspension
system
^ Any rear spring which is unfolded must be refolded prior to being installed in a vehicle.
^ The air spring refolding procedure should only be used for an air spring which has never
supported the vehicle's weight while in the improperly folded position.
^ Improperly folded air springs found on vehicles during pre-delivery inspection or after use must
be replaced.
^ Do not attempt to inflate any air spring which has been collapsed while uninflated from the
rebound hanging position to the jounce stop.
^ When installing a new air spring, care must be taken not to apply a load to the suspension until
springs have been inflated using the air spring fill procedure.
^ After inflating an air spring in hanging position, it must be inspected for proper shape.
NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air
suspension system.
Deflate the air suspension system.
2. WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the
air suspension switch located on the LH side of the luggage compartment to prevent vehicle
damage or personal injury.
Turn the air suspension switch off.
3. Raise and support the vehicle.
4. Remove the rear air spring retainer.
5. Lift the bottom of the air spring off the rear axle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6570
6. Remove the air spring.
1 Disconnect the electrical connector.
2 Push on the red air line retaining ring and disconnect the air line.
3 Remove the air spring.
Installation
1. CAUTION: To avoid damage to the air spring, do not allow suspension to compress before the
spring is inflated.
Install the air spring. 1
Position the air spring assembly in the frame seat.
2 Install the spring retainer clip.
2. Seat the bottom of the air spring on the rear axle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Page 6571
3. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
Connect the air spring solenoid valve. 1
Connect the electrical connector.
2 Connect the air line.
3 Make sure air spring is in the proper shape with no folds or creases.
4. Refill the air springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications
Compressor/Pump: Specifications
Retaining Bolts ....................................................................................................................................
................................... 7.6-10.4 Nm (68-88 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6575
Compressor/Pump: Description and Operation
NOTE: The compressor contains a thermal overload circuit breaker. The circuit breaker
automatically resets after a cool down period and after being if tripped by excessive compressor
motor heat.
The air compressor assembly consists of the compressor pump, electric motor and vent solenoid
(must be installed as an assembly).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6576
Compressor/Pump: Service and Repair
Removal
WARNING: Do not remove an air spring under any circumstances when there is pressure in the air
spring. Do not remove any components supporting an air spring without either exhausting the air or
providing support for the air spring to prevent vehicle damage or personal injury.
WARNING: Disconnecting an air line that is connected to the air compressor can cause personal
injury or damage to components as high pressure air is vented uncontrolled.
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Remove the
Engine Air Cleaner (ACL).
4. Remove the air compressor and air compressor drier cover.
1 Remove the pushpins.
2 Remove the air compressor and air compressor drier cover.
5. Remove the snorkel pushpin and remove the snorkel.
6. Remove the air compressor and air compressor drier.
1 Compress the quick connect locking ring and pull out the air line.
2 Disconnect the electrical connector.
3 Remove the three bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6577
4 Remove the air compressor and air compressor drier.
Installation
1. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
NOTE: After installing the air compressor, it is necessary to inflate the air suspension system.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6581
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6582
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Diagnostic Connector, Suspension > Component Information > Locations
Diagnostic Connector: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Diagnostic Connector, Suspension > Component Information > Locations > Page 6586
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Functional
Level Control Solenoid Valve: Service and Repair Functional
Removal
WARNING: Do not remove an air spring under any circumstances when there is pressure in the air
spring. Do not remove any components supporting an air spring without either exhausting the air or
providing support for the air spring to prevent vehicle damage or personal injury.
WARNING: Disconnecting an air line that is connected to the air compressor can cause personal
injury or damage to components as high pressure air is vented uncontrolled.
1. Remove the air spring.
2. CAUTION: Remove any dirt or other debris from the air spring assembly before removing the air
spring solenoid.
NOTE: The air spring solenoid valve has a two stage solenoid valve pressure relief fitting similar to
a radiator cap.
Release the air pressure. 1
Rotate the air spring solenoid valve counterclockwise to the first stop.
2 Pull the air spring solenoid valve out to the stop.
3. WARNING: Do not fully release solenoid air valve until air is completely bled from the air spring
to prevent injury.
Rotate the air spring solenoid valve counterclockwise to the second stop and remove from the
solenoid valve housing.
Installation
1. NOTE: Check the solenoid valve O-rings for abrasion or cuts. Replace O-rings as required using
air spring connector repair kit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 6591
NOTE: Lightly apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or
equivalent meeting Ford specification ESE-M1C171-A to the O-rings.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 6592
Level Control Solenoid Valve: Service and Repair Non-Functional
Removal
WARNING: Do not remove an air spring under any circumstances when there is pressure in the air
spring. Do not remove any components supporting an air spring without either exhausting the air or
providing support for the air spring to prevent vehicle damage or personal injury.
NOTE: The air spring solenoid has a two-stage pressure relief fitting similar to a radiator cap.
1. Turn the air suspension switch off. 2. Raise and support the vehicle.
3. Disconnect the air spring solenoid electrical connector and air line.
1 Disconnect the electrical connector.
2 Compress the quick connect locking ring and pull out the air line.
4. CAUTION: Remove any dirt or other debris from the air spring prior to removing the air spring
solenoid from the air spring.
Remove the air spring solenoid clip.
5. Rotate the air spring solenoid out of the air spring to the first detent to release the air from the air
spring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 6593
6. Twist the solenoid valve and remove.
Installation
1. NOTE: Be sure the new air spring solenoid is fully seated into both stages of the air spring.
NOTE: Check the solenoid valve O-rings for abrasion or cuts. Replace O-rings as required using
air spring connector repair kit.
NOTE: Lightly apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or
equivalent meeting Ford specification ESE-M1C171-A to the O-rings.
NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
To install, reverse removal procedure. ^
After installing the solenoid, it is necessary to inflate the air suspension system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Specifications
Ride Height Sensor: Specifications
Mounting Bracket To Lateral Arm
...........................................................................................................................................................
14 Nm (10 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Specifications > Page 6597
Ride Height Sensor: Description and Operation
The air suspension height sensor sends signals to the air suspension control module. There are
three possible conditions that the air suspension control module interprets from the signals of the
air suspension height sensors. The conditions are trim height, below trim height, or above trim
height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Specifications > Page 6598
Ride Height Sensor: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Turn the air suspension switch off. 3. Raise and support
the vehicle.
4. Disconnect the air suspension height sensor electrical connector.
5. Remove the air suspension height sensor.
^ Depress the metal retaining tabs and remove the air suspension height sensor from the ball
studs.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Retaining Screws .................................................................................................................................
..................................... 2.3-3.3 Nm (20-29 inch lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 6602
Suspension Control Module: Locations
An A-to-Z electrical components location list can be viewed at Vehicle/Locations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 6603
Suspension Control Module: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 6604
Suspension Control Module: Description and Operation
A microprocessor controls the air suspension system. The microprocessor and its supporting
hardware are contained in the air suspension control module. The air suspension control module
responds to signals from various sensors in the vehicle to maintain the programmed ride height
while the vehicle is either moving or stopped. The air suspension control module accomplishes this
by opening and closing solenoid valves to control the amount of air in the air spring(s). The air
suspension control module turns on the compressor by applying voltage through the compressor
relay to inflate the air spring(s) and raise the vehicle. The air suspension control module opens the
vent solenoid to lower the vehicle by releasing air from the air spring(s)in response to signal inputs
from the air suspension height sensor(s).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 6605
Suspension Control Module: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Pull out the lower instrument panel insulator.
1 Remove the pushpins.
2 Pull out the lower instrument panel insulator.
4. Remove the lower instrument panel insulator.
1 Disconnect the power point.
2 Disconnect the courtesy lamp.
3 Remove the lower instrument panel insulator.
5. Remove the rear air suspension control module.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the rear air suspension control module.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 6606
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Mode Switch > Component Information > Description and Operation
Suspension Mode Switch: Description and Operation
CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is
hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of
the system and possible damage to the air suspension system components.
The air suspension switch provides a signal to the air suspension control module in the ON position
to activate the system to maintain the programmed vehicle height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Mode Switch > Component Information > Description and Operation > Page 6610
Suspension Mode Switch: Service and Repair
Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the
power to the system by turning off the air suspension switch located on the LH side of the luggage
compartment to prevent vehicle damage or personal injury.
1. Turn the air suspension switch off. 2. Disconnect the battery ground cable.
3. Peel back the luggage compartment trim.
1 Remove the pushpins.
2 Peel back the luggage compartment trim.
4. Remove the air suspension switch.
1 From behind the quarter panel reinforcement, depress the clips.
2 Remove the air suspension switch.
5. Disconnect the electrical connector.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Warning Indicator > Component Information > Description and Operation
Suspension Warning Indicator: Description and Operation
The CHECK AIR SUSPENSION warning indicator illuminates when a concern in the air suspension
system is detected or when the air suspension switch is in the OFF position. During prove-out,
when a concern is detected or the air suspension switch is OFF, an audible tone will sound and the
CHECK AIR SUSPENSION warning indicator will flash on and off for five seconds. The CHECK
AIR SUSPENSION warning indicator will then remain illuminated until the concern is corrected or
the air suspension switch is switched ON.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 >
A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Suspension Spring ( Coil / Leaf ): Customer Interest A/T - 4R70W Vibration/Fluid Leak At
Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 >
A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6622
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 99-18-1 > Sep > 99 >
A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6623
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 99-18-1 >
Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing
Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins A/T - 4R70W Vibration/Fluid Leak
At Extension Housing
Article No. 99-18-1
09/06/99
^ CALIBRATION - MAXIMUM SPEED RECALIBRATION TO 126 MPH (202 KM/H) - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
^ TRANSMISSION - 4R70W - VIBRATION/FLUID LEAK AT EXTENSION HOUSING - CROWN
VICTORIA POLICE VEHICLES BUILT THROUGH 7/30/1999 ONLY
FORD: 1999 CROWN VICTORIA
ISSUE Some 1999 Crown Victoria Police vehicles may exhibit a vibration and/or transmission fluid
leak from the extension housing seal area. This may be due to extended high speed operation
which may cause the extension housing bushing or seal to walk/spin out due to excessive
driveshaft flexing.
ACTION Inspect the extension housing bushing. If the extension bushing/seal is spun and/or has
walked out, replace the extension housing assembly and gasket. Verify the vehicle has "GNX" level
rear springs and that the revised Metal Matrix Composite (MMC) driveshaft is installed. The revised
driveshaft does not flex as much during sustained high speed operation and should reduce the
possibility of fluid leaks. Refer to the following Service Procedure for details
SERVICE PROCEDURE
1. Raise the vehicle on a hoist and inspect the transmission extension bushing for damage and
transmission fluid leaking from the extension housing seal area. In addition, verify that the vehicle
is equipped with the MMC driveshaft and the latest level coil springs (GNX). The MMC driveshaft
can be identified by the pink/green stripes around the driveshaft tube. The aluminum driveshaft will
have pink/blue/orange stripes.
2. If the bushing is found to be damaged, remove the driveshaft and transmission extension
housing per the appropriate Workshop Manual Section.
3. Replace the Extension Housing Assembly (F5UZ-7A039-A) and Extension Housing Gasket
(F7AZ-7086-A) following the procedure outlined in the Workshop Manual.
4. If the vehicle is equipped with an aluminum driveshaft, the driveshaft must be replaced with the
revised MMC Driveshaft (XW7Z-4602-AA).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 99-18-1 >
Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6629
NOTE
THE INDEX MARKS ON THE OUTPUT SHAFT, DRIVESHAFT, AND REAR AXLE MUST BE
ALIGNED. THE BALANCE MARK ON THE OUTPUT SHAFT AND THE BALANCE MARK ON THE
DRIVESHAFT MUST BE ALIGNED (FIGURE 1). FURTHER, ALIGNMENT OF THE INDEX
MARKS ON THE REAR DRIVESHAFT TUBE AND REAR AXLE FLANGE MUST BE
PERFORMED (FIGURE 2).
5. If the vehicle is equipped with "EPS" level rear springs, replace the rear springs with the revised
"GNX" level Springs (F8AZ-5560-GA). Refer to the Workshop Manual for details.
6. Using New Generation Star (NGS) Tester, check the Powertrain Control Module (PCM)
calibration. Refer to Step 7.
7. Access PCM, select "MODULE I.D.". If the module part number is XW7F-CE then the vehicle
has the latest level calibration (9VNA-AA) with a vehicle maximum speed of 202 km/h (126 mph).
Do not reprogram the PCM. If the module l.D. is not XW7F-CE, reprogram the PCM to the latest
level (9VNA-AA) using an NGS Tester or Service Bay Diagnostic System (SBDS).
8. Verify transmission fluid level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 99-18-1 >
Sep > 99 > A/T - 4R70W Vibration/Fluid Leak At Extension Housing > Page 6630
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list
the date, dealer number, and summary of modifications performed. Select a prominent place
adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized
Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME
F5UZ-7A039-A Extension Housing Assembly
F7AZ-7086-A Gasket
XW7Z-4602-AA Driveshaft
F8AZ-5560-GA Rear Coil Springs
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
991801A Replace Extension And 1.6 Hrs.
Driveshaft Housing Assembly (Do Not Use With Operation B)
991801B Replace Driveshaft 0.7 Hr.
Assembly Only If Required (Do Not Use With Operation A)
991801C Replace Rear Springs 0.9 Hr.
991801D Inspect For Calibration 0.3 Hr.
991801E Reprogram Powertrain 0.3 Hr.
Control Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4602 02
OASIS CODES: 501000, 503000, 504000, 510000, 597997, 614000, 614600, 703000, 703200,
703300, 703400
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Page 6631
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front
Suspension Spring ( Coil / Leaf ): Service and Repair Front
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. They must be
replaced with the same part number or an equivalent part if replacement is necessary. Do not use
a replacement part of lesser quality or substitute design. Torque values must be used during
reassembly to ensure proper retention of these parts.
1. Mark the relative position of the front suspension lower arm to the frame with the vehicle in a
static, level ground position (curb height). 2. Raise and support the vehicle. 3. Remove the front
wheel and tire assemblies.
4. Remove the shock absorber lower mounting bolts
5. Remove the front shock absorber.
1 Remove the nut, retainer and grommet.
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Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 6634
2 Remove the shock absorber.
6. Using the special tool, compress the front coil spring until it is free in its front spring insulator.
7. Remove the front coil spring.
1 Remove the bolts and nuts.
2 Pivot the front suspension lower arm. Remove the front coil spring.
Installation
1. With the front coil spring compressed, position the spring on the lower control arm.
2. NOTE: Do not tighten the front suspension lower arm bolts until the suspension is at curb height.
Install the front suspension lower arm. 1
Position the front suspension lower arm.
2 Install the bolts and nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 6635
3. Make sure the front spring insulator is properly seated and remove the special tool 204-D00
(D78P-5310-A).
4. Install the shock absorber.
1 Position the shock absorber through the upper shock mount.
2 Install the grommet, retainer and nut, and tighten.
5. Install the shock absorber lower mounting bolts.
6. Position a jack stand under the front suspension lower arm and raise the suspension until the
marks on the front suspension lower arm and the
frame made in removal, step 1 are aligned (curb height).
7. Tighten the bolts. 8. Lower the suspension and remove the jack stand. 9. Install the front wheel
and tire assemblies.
10. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 6636
Suspension Spring ( Coil / Leaf ): Service and Repair Rear
Rear Suspension
Removal
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Mark the rear shock absorber relative to the protective sleeve with the vehicle in a static, level
ground position (curb height). 2. Raise the vehicle on a hoist. 3. Remove both wheel and tire
assemblies.
4. Disconnect the stabilizer bar from the stabilizer bar links.
1 Remove the nuts and the bushings.
2 Rotate the stabilizer bar off the links.
5. Use the special tool 014-0094 or equivalent to support the rear axle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 6637
6. Remove the nuts and bolts and disconnect the lateral arms from the frame. Discard the nuts and
bolts.
7. WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend
unassisted. Do not apply heat or flame to
the shock absorbers during removal or component servicing. Failure to follow these instructions
can result in personal injury.
Remove the nuts and disconnect the shock absorbers from the axle. Discard the nuts.
8. Carefully lower the special tool.
9. Remove the springs and spring insulators.
Installation
1. Inspect the spring insulators for wear or damage. Install new insulators if necessary.
2. Install the spring insulators on the springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 6638
3. Install the springs and the spring insulators in the vehicle. Make sure the springs are properly
seated. 4. Raise the axle using the special tool.
5. Connect the shock absorbers to the axle and install new nuts.
6. Connect the lateral arms to the frame and install new bolts and nuts. Do not tighten at this time.
7. Using the special tool, raise the axle until the shock absorber is compressed to the previously
established alignment mark (curb height).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 6639
8. Tighten both bolts. 9. Lower the axle and remove the special tool.
10. Connect the stabilizer bar to the stabilizer bar links.
1 Rotate the stabilizer bar onto the links and install the bushings.
2 Install the nuts.
11. Install the wheel and tire assemblies. 12. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Page 6640
Suspension Spring ( Coil / Leaf ): Tools and Equipment
Rear Suspension
Special Tool
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications
Suspension Strut / Shock Absorber: Specifications
Mounting Bolts/Nuts
Front
Upper ...................................................................................................................................................
........................................... 40 Nm (30 ft. lbs.) Lower .........................................................................
..................................................................................................................... 15 Nm (11 ft. lbs.)
Rear
Upper ...................................................................................................................................................
........................................... 40 Nm (30 ft. lbs.) Lower .........................................................................
..................................................................................................................... 90 Nm (66 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > With Air Suspension
Suspension Strut / Shock Absorber: Service and Repair With Air Suspension
Rear Suspension
Removal
WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend
unassisted. Do not apply heat or flame to the shock absorbers during removal or component
servicing. Failure to follow these instructions can result in personal injury.
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off.
2. Raise and support the vehicle.
3. Use the special tool 014-0094 or equivalent to support the rear axle.
4. WARNING: Do not remove an air spring under any circumstances when there is air pressure in
the air spring. Do not remove any
components supporting an air spring without exhausting the air.
Release the air pressure from the air springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > With Air Suspension > Page 6646
5. NOTE: Replace shock absorbers individually as required. It is not necessary to replace in pairs.
NOTE: To assist in removing the upper attachment on shock absorbers, use a plastic dust tube
and place an open end wrench on the hex stamped into the dust tube's metal cap. For shock
absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the
retaining nut.
Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper
side of the frame.
6. Remove and discard the nut. Disconnect the shock absorber lower stud from the mounting
bracket on the rear axle assembly.
Installation
1. To install, reverse the removal procedure.
2. Inflate the air springs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > With Air Suspension > Page 6647
Suspension Strut / Shock Absorber: Service and Repair Without Air Suspension
Rear Suspension
Removal
WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend
unassisted. Do not apply heat or flame to the shock absorbers during removal or component
servicing. Failure to follow these instructions can result in personal injury.
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital
components and their failure can result in major service expense. They must be replaced with the
same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used during reassembly to ensure
proper retention of these parts.
1. Raise and support the vehicle.
2. Use the special tool 014-0094 or equivalent to support the rear axle.
3. NOTE: Replace shock absorbers individually as required. It is not necessary to replace in pairs.
NOTE: To assist in removing the upper attachment on shock absorbers, use a plastic dust tube
and place an open end wrench on the hex stamped into the dust tube's metal cap. For shock
absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the
retaining nut.
Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper
side of the frame.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > With Air Suspension > Page 6648
4. Remove and discard the nut. Disconnect the shock absorber lower stud from the mounting
bracket on the rear axle assembly.
Installation
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Page 6649
Special Tool
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information
> Specifications
Suspension Travel Bumper: Specifications
Retaining Nuts .....................................................................................................................................
...................................................... 40 Nm 30 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6657
Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6659
Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6660
The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6661
The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6662
Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6663
Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6664
The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6692
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6693
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6694
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6695
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6696
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6697
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6698
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6699
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6700
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6701
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6705
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6706
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6708
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6710
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6711
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6712
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Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6713
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6715
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6716
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6717
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6718
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6719
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6720
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6721
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6722
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6723
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6724
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6725
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6726
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6727
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6738
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6741
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6742
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
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Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6744
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6745
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6746
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6747
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6748
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6749
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6750
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6751
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 6752
Wheel Bearing: Service Precautions
CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the
improper grease can cause bearing damage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 6753
Wheel Bearing: Testing and Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new
wheel hub.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 6754
Wheel Bearing: Service and Repair
FRONT WHEEL HUB
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. Remove and discard the front hub cap grease seal.
5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it
can back off resulting in loss of the front
wheel and or damage to the wheel hub and bearing assembly.
Remove the front axle wheel hub retainer. Discard the retainer.
6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS
sensor lead or the ABS sensor ring.
NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to
remove.
Remove the wheel hub and bearing assembly.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 6755
1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the
ABS sensor lead or the ABS sensor ring.
Install the wheel hub and bearing assembly.
2. Install a new front axle wheel hub retainer.
3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire
assembly. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Axle Wheel Hub Retainer
...........................................................................................................................................................
300 Nm (221 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
Technical Service Bulletin # 00S13 Date: 000701
Recall - Vehicle Jacking Procedure
SAFETY RECALL 00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment II ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6769
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought
to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6770
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of
the Owner Letter and schedule a service date.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARS Rental vehicles are not approved for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage
label, and a jack usage and stowage placard will be sent directly to owners, along with instructions
on placement of the various pieces. This will be a "no charge" service and customers will be
directed to follow the attached instructions for proper placement of the labels and owner guide
supplement.
Additional owner packages containing the above mentioned items can be ordered by calling the
Recall Hotline at 1-800-325-5621.
Attachment III - Technical Information
OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the
vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.
^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6771
1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located
in the glove compartment. See Figure 1.
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by
removing the right quarter trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6772
2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the
underside of the spare tire cover.
1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and
Stowage label directly over the original label as illustrated. See Figure 3.
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6773
1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing
Instruction placard on top of the spare tire as illustrated. See Figure 4.
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6774
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page
6775
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure
Technical Service Bulletin # 00S13 Date: 000701
Recall - Vehicle Jacking Procedure
SAFETY RECALL 00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment II ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6781
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation
of this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford
Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought
to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6782
DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of
the Owner Letter and schedule a service date.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARS Rental vehicles are not approved for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage
label, and a jack usage and stowage placard will be sent directly to owners, along with instructions
on placement of the various pieces. This will be a "no charge" service and customers will be
directed to follow the attached instructions for proper placement of the labels and owner guide
supplement.
Additional owner packages containing the above mentioned items can be ordered by calling the
Recall Hotline at 1-800-325-5621.
Attachment III - Technical Information
OVERVIEW There are four (4) items revising the jacking instructions that must be placed in the
vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.
^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6783
1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located
in the glove compartment. See Figure 1.
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by
removing the right quarter trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6784
2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the
underside of the spare tire cover.
1. Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and
Stowage label directly over the original label as illustrated. See Figure 3.
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6785
1. Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing
Instruction placard on top of the spare tire as illustrated. See Figure 4.
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6786
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
Jacking Procedure > Page 6787
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Page 6788
Vehicle Lifting: Description and Operation
JACKING
WARNING
^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO
THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE.
THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE
AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE
LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF
THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE
OPERATIONS.
^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO
MOVE.
CAUTION
^ The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose. Refer to the Owner Guide when using the jack supplied with the vehicle.
^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer
or differential housing. Severe damage to the vehicle could result.
^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure.
Jacking Points
Push the air suspension service switch to the OFF position.
To lift the front or either side of the front end, position the floor jack or the hoist under the front
frame lift points.
To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift
points.
LIFTING
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER
SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE
VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING
OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT
ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
CAUTION
^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Page 6789
^ Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.
Lift the vehicle using the Lifting Points procedure.
Lifting Points-Drive-On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the
drive-on hoist without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance.
Lifting Points-Two Post Lift
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Page 6790
Lifting Points-Single-Post Hoist
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Page 6791
Vehicle Lifting: Service and Repair
JACKING
WARNING
^ ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY TO
THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO JACKING THE VEHICLE.
THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING OFF THE
AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE
LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF
THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE
OPERATIONS.
^ NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN
CHANGING A TIRE. THE WHEEL STILL ON THE GROUND COULD CAUSE THE VEHICLE TO
MOVE.
CAUTION
^ The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose. Refer to the Owner Guide when using the jack supplied with the vehicle.
^ Under no circumstances should the vehicle ever be lifted by the front control arms, rear stabilizer
or differential housing. Severe damage to the vehicle could result.
^ Do no attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure.
Jacking Points
Push the air suspension service switch to the OFF position.
To lift the front or either side of the front end, position the floor jack or the hoist under the front
frame lift points.
To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift
points.
LIFTING
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER
SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO LIFTING THE
VEHICLE. THIS CAN BE ACCOMPLISHED BY DISCONNECTING THE BATTERY OR TURNING
OFF THE AIR SUSPENSION SERVICE SWITCH LOCATED IN THE LUGGAGE COMPARTMENT
ON THE LH SIDE. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
CAUTION
^ Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar,
rear subframe stabilizer brackets or to compress the lower suspension arm stabilizer bar insulator.
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Page 6792
^ Never use the differential housing as a lift point. Damage to the differential housing and cover
may occur.
Lift the vehicle using the Lifting Points procedure.
Lifting Points-Drive-On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the
drive-on hoist without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance.
Lifting Points-Two Post Lift
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Technical Service Bulletins > Page 6793
Lifting Points-Single-Post Hoist
CAUTION: Under no circumstances should the vehicle be lifted by the front control arms or rear
control arms. Severe damage to the vehicle could result.
NOTE: Wheel adapters must be used under the tires when lifting the vehicle with a single-post
hoist.
Lift the vehicle at the applicable lift points.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information >
Specifications
Spare Tire: Specifications
Wheel Size ..........................................................................................................................................
...................................................................... 16 x 4.5 Bolt Circle .......................................................
...................................................................................................................................... 114.3 mm
(4.5 inch) Lugs .....................................................................................................................................
................................................................................................. 5 Offset ..............................................
..............................................................................................................................................................
............ 9 (inset) Tire Usage ................................................................................................................
............................................................................... T145/80D16 105M
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels
Wheels: Customer Interest Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on
Wheels
Wheels: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels
Article No. 02-11-2
06/10/02
BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS
FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002
ESCAPE
MERCURY: 1999-2003 GRAND MARQUIS
ISSUE
Under normal operating conditions, customers may notice accumulation of brake dust on their
wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The
use of modern friction materials with emphasis on improved performance and environmental
considerations can lead to more dust than in the past.
ACTION
Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft
sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A).
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 108000, 301000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force
Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force
Measurement Equipment > Page 6815
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
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Diagnosis
Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
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Diagnosis > Page 6821
For Dealerships without An Electronic Vibration Analyzer
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Diagnosis > Page 6822
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Diagnosis > Page 6823
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
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Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
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Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6840
Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6841
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6842
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6843
To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6844
^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6845
speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6846
Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6847
^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6848
^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6849
- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6850
Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Noise/Vibration/Harshness Procedure > Page 6873
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6874
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6875
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6876
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6877
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6878
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6879
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6880
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6881
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6882
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6883
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6884
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6885
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6886
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6887
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6888
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6889
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6890
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6891
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6892
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6893
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6894
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6895
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6896
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6897
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6898
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6899
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6900
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6901
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6902
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6903
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6904
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6905
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6906
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6907
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6908
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6909
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6910
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6911
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6912
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6913
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6914
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6915
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6916
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6917
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6918
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6919
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6920
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6921
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6922
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6923
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
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Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 6929
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 01-1-14 > Jan > 01 > Suspension/Driveline - Vibration
Diagnosis
Wheels: All Technical Service Bulletins Suspension/Driveline - Vibration Diagnosis
Article No. 01-1-14
01/22/01
^ SUSPENSION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
^ VIBRATION - VIBRATION FELT AT SPEEDS ABOVE 72 KM/H (45 MPH)
FORD: 1999-2001 CROWN VICTORIA
MERCURY: 1999-2001 GRAND MARQUIS
ISSUE Some vehicles may exhibit driveline vibrations at speeds in excess of 72 km/h (45 mph)
which may be related to driveshaft, axle, wheels, or their components.
ACTION Identify the causal component for the vibration and balance or replace as necessary to
eliminate the vibration. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
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Diagnosis > Page 6934
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Diagnosis > Page 6935
For Dealerships without An Electronic Vibration Analyzer
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Diagnosis > Page 6936
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Diagnosis > Page 6937
For Dealerships with An Electronic Vibration Analyzer
Refer to the Diagnostic Flowcharts as shown in (Figures 1-5) as an aid in diagnosing vibration
conditions.
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Diagnosis > Page 6938
Driveline Vibration Data Sheet
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 504000, 509000, 597997, 703000, 703200, 703300, 703400
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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Noise/Vibration/Harshness Procedure > Page 6952
engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6953
^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6954
Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6955
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6956
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6957
To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6958
^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6959
speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6960
Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6961
^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6962
^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6963
- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6978
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6979
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6980
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6981
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6982
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6983
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6984
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6985
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6986
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6987
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6988
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6989
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6990
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6991
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6992
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6993
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6994
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6995
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6996
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6997
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6998
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 6999
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7001
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7002
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7003
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7004
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7005
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7006
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7007
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7008
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7009
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7010
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7011
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7012
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7013
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7014
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7015
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7016
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7017
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7018
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7019
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7020
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7021
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7022
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7023
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7024
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7025
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7026
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7027
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7028
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7029
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7030
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7031
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7032
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7033
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7034
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7035
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive
Noise/Vibration/Harshness Procedure > Page 7036
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
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Noise/Vibration/Harshness Procedure > Page 7037
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 7038
Wheels: Specifications
Bolt Circle ............................................................................................................................................
................................................. 114.3 mm (4.5 inch) Balance Weights, Max.
Per Wheel ............................................................................................................................................
...................................................... 140 g (5.0 oz.) Per Side ................................................................
......................................................................................................................................... 70 g (2.5
oz.)
Lugs .....................................................................................................................................................
................................................................................. 5 Offset
Steel ....................................................................................................................................................
.......................................................................... 11 Aluminum .............................................................
.........................................................................................................................................................
4.5
Runout, Max
Radial ..................................................................................................................................................
............................................. 0.64 mm (0.025 inch) Lateral .................................................................
............................................................................................................................. 0.89 mm (0.035
inch)
Size ......................................................................................................................................................
......................................................................... 16 x 7
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
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Wheels: Testing and Inspection
TIRE AND WHEEL RUNOUT
Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration,
wheel tramp, tire wear, and steering wheel tremor.
Before checking runout, and to avoid false readings caused by temporary flat spots in the tires,
check runout only after the vehicle has been driven far enough to warm the tires.
The extent of the runout is measured with the radial runout gauge. All measurements are made on
the vehicle with the tires inflated to recommended inflation pressures.
TIRE RUNOUT
Measure radial and lateral tire runout at the positions shown in the illustration. Runout should not
exceed specifications.
WHEEL RUNOUT
Measure radial and lateral wheel runout at the positions shown in the illustration. Runout should not
exceed specifications. Note that the tire has been removed.
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Leaks
Wheels: Service and Repair Leaks
NOTE: Wheel repairs that use welding or peening are not approved. An inner tube is not an
acceptable repair for leaking wheels or tires.
If the air pressure in a tire mounted on an aluminum wheel is found to be low, perform the following
procedure before considering wheel replacement.
1. Remove the tire and wheel assembly, and inspect the wheel for structural damage. If none
exists, go to Step 2. If the wheel is damaged, install new. 2. With the tire mounted on the wheel,
locate the air leak using a water bath or equivalent method, and mark the location. Check the
complete wheel
for possible additional leaks. When leaks are marked, dismount the tire marking valve location on
the tire for correct indexing.
3. On the tire side of the wheel, thoroughly clean the leaking area with an appropriate cleaner
(Professional Choke and Linkage Cleaner
E8AZ-19A501-AA or equivalent meeting Ford specification ESR-M14P10-A) or use sandpaper of
approximately 80-grit to remove all contamination. Using the sandpaper, score the surface of the
leaking area to improve adhesion of the sealer. If the valve stem is close to the area, remove it.
4. Use a clean cloth to remove all cleaner or sanding dust.
5. NOTE: Do not use a torch containing oxyacetylene.
Heat the prepared area with a Heat Gun or a propane torch until Aluminum Wheel Repair
Compound E7AZ-19554-A or equivalent meeting Ford specification ESA-M4G280-A flows. Apply
the hot melt material over the prepared area using a liberal flow and wiping action. Repair is most
effective when heat is applied to the brake side of the rim, and the sealer is melted by heat in the
metal.
6. Apply only enough heat to melt the sealer, then remove the heat source. After repairing the leak,
allow the wheel to cool until it can be handled
safety.
7. CAUTION: Use caution when mounting the tire so as not to damage the sealer.
Index and assemble the tire and wheel. Inflate the tire to the recommended pressure as indicated
on the tire pressure decal.
8. Repeat Step 2 to verify repair. 9. When the repair is completed, balance the assembly and install
it on the vehicle.
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Repair > Leaks > Page 7042
Wheels: Service and Repair Replacement
Removal
1. Loosen the lug nuts.
1 Remove the wheel cover or ornament.
2 CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel
bearings.
Loosen, but do not remove the lug nuts.
2. CAUTION: Never use the differential housing as a lift point.
Raise the vehicle until the tire clears the floor.
3. CAUTION: Do not use heat to loosen a frozen wheel because heat can shorten the life of the
wheel and damage the wheel bearings. If the
wheel cannot be removed by hand, use a wheel puller to remove the frozen wheel.
Remove the wheel and tire from the vehicle. ^
Remove the lug nuts.
^ Remove the wheel and tire.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug
nuts to loosen and the wheel to come off while the vehicle is in motion, resulting in loss of control.
Position the wheel and tire on the vehicle.
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Repair > Leaks > Page 7043
2. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of
brake roughness, shudder and vibration.
Tighten the lug nuts to specification in a star-pattern sequence.
3. Install the wheel cover or ornament.
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Technical Service Bulletin # 99-11-1 Date: 990614
Comprehensive Noise/Vibration/Harshness Procedure
Article No. 99-11-1
06/14/99
^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE,
EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION,
MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness
(NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop
Manuals in the NVH Section.
ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to
COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH
diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A
revised NVH course is available through regional training centers. The course is "NVH Principals
and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the
revised diagnostic procedure.
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 497000, 597997, 701000, 702000, 703000
SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and
Harshness
CONTENTS
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic
Theory Diagnostic Process Glossary of Terms Tools and Techniques
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
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Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer
Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down.
Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the
customer. Harshness normally describes a firmer than usual response from the suspension
system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which
customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH
caused by road and environmental conditions is normal. This section is designed to aid in the
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a
real world environment adds noise that is not subject to control. Vibration isolators, mufflers and
dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that
some sounds are abnormal when actually the sounds are normal for the vehicle type. For example,
Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving.
This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is
very important to be familiar with vehicle features and know how they relate to NVH concerns and
their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the
vehicle both in and out of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
^ system knowledge, including comparison with a known good system.
^ system history, including repair history and usage patterns.
^ condition history, especially any relationship to repairs or sudden change.
^ knowledge of probable causes
^ using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
^ a road or system test to determine the exact nature of the concern.
^ an analysis of the possible causes.
^ testing to verify the cause.
^ repairing any concerns found.
^ a road test or system test to make sure the concern has been corrected or brought back to within
a acceptable range.
Diagnostic Process
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. The following flowcharts are a graphic representation of the diagnostic process. Use the
flowcharts as follows:
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.
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^ Advance through the flowchart from left to right.
^ Match the operating condition to the symptom.
^ Verify the symptom.
^ Identify which category or system could cause the symptom.
^ Refer to the diagnostic symptom chart that the flowchart refers to.
Glossary of Terms
Acceleration-Light An increase in speed at less than half throttle.
Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60
mph) in approximately 30 seconds.
Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph)
in approximately 20 seconds.
Ambient Temperature The surrounding or prevailing temperature.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An
extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Backlash Gear teeth clearance.
Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to
Drumming.
Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of
absorbing it.
Brakes Applied When the service brakes are applied with enough force to hold the vehicle against
movement with the transmission in gear.
Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound.
Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor.
Camber The angle of the wheel in relation to the true vertical as measured looking from the front of
the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is
positioned away from the vehicle.
Caster The angle of the steering knuckle in relation to the true vertical as measured looking from
the side of the vehicle.
Chatter A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp A short-duration high-pitched noise associated with a slipping drive belt.
Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.
Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also
described as hammering.
Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a
vehicle that is accelerating or decelerating abruptly. Also described as a thunk.
Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle
speed without applying the brakes.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the
clutch pedal while at cruise.
Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being
transmitted at an angle.
Controlled Rear Suspension Height The height at which a designated vehicle element must be
when driveline angle measurements are made.
Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear
driveshaft, the front section.
CPS Cycles per second. Same as hertz (Hz).
Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak A metallic squeak.
Cruise Constant speed on level ground; neither accelerating nor decelerating.
Cycle The process of a vibrating component going through a complete range of motion and
returning to the starting point.
Decibel A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with
the vehicle standing still, the brakes applied and the transmission engaged. This test is used for
noise and vibration checks.
Driveline Angles The differences of alignment between the transmission output shaft, the drive
shaft, and the rear axle pinion centerline.
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece
driveshaft, it is the rearmost shaft.
Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or
torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle.
It is tuned by weight and placement to absorb vibration.
Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a
moan.
Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation
of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder.
Dynamic Balance
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The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation
center. Excessive motion.
Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong
time.
Engine Shake An exaggerated engine movement or vibration that directly increases in frequency
as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or
reciprocating components.
Flexible Coupling A flexible joint.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches
the engine speed with the road speed.
Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the
wind.
Frequency The rate at which a cycle occurs within a given time.
Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on
gravel.
Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Howl A mid-range frequency noise between drumming and whine.
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
Hz Hertz; a frequency measured in cycles per second.
Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance
often causes vibration.
Inboard Toward the centerline of the vehicle.
Intensity The physical quality of sound that relates to the strength of the vibration (measured in
decibels). The higher the sound's amplitude, the higher the intensity and vice versa.
Isolate To separate the influence of one component to another.
Knock A heavy, loud, repetitious sound, like a knock on the door.
Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test
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The operation of the engine through the normal rpm range with the vehicle standing still and the
transmission disengaged. This test is used to identify engine related vibrations.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound
Up.
NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense
and result in varying degrees of dissatisfaction.
Outboard Away from the centerline of the vehicle.
Ping A short duration, high-frequency sound, which has a slight echo.
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input
hypoid gear of a ring and pinion gearset.
Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency
increases and vice versa.
Pumping Feel A slow, pulsing movement.
Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
Rattle A random and momentary or short duration noise.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Road Test The operation of the vehicle under conditions intended to produce the concern under
investigation.
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake.
This type of vibration is usually related to drivetrain components.
Runout Out of round and wobble.
Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through
leaves.
Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually
relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is
engine speed sensitive. Also referred to as a shimmy or wobble.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in
the driveshaft rotation. Also described as waddle.
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Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake
application.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the
suspension articulates and while the driveshaft rotates.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal A long-duration, high-pitched noise.
Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and
tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually
cause uneven tire wear.
Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump A dull beat caused by two items striking together.
Tick A rhythmic tap, similar to a clock noise.
Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100
km/h (25-65 mph).
TIR Total indicated run out
Tire Deflection The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire
wear patterns in the tire tread resulting from wheel-locked skids.
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Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is
noticeable when the tire rotates against the pavement. This condition can be present on perfectly
round tires because of variations in the inner tire construction. This condition can occur at wheel
rotation frequency or twice rotation frequency.
Transient Momentary, short duration.
Two-Plane Balance Radial and lateral balance.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back
and forth or up and down.
Whine A constant, high-pitched noise. Also described as a screech.
Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle
noises are a turbocharger or airflow around an antenna.
Wind Noise Any noise caused by air movement in, out or around the vehicle.
WOT Wide-open throttle
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe
balancing function that can be used to detect imbalance on rotating components such as a
driveshaft or engine accessories.
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The EVA allows for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
- If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
- A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or
rear wheels and tires.
c. Record the readings. Also note when the condition begins when it reaches maximum intensity.
and if it tends to diminish above/below a certain speed.
- Frequencies should be read in the "avg" mode.
- Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear
axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear
axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5
mph) X 3.08 (rear axle ratio) = 30.8 Hz.
e. Place the vibration sensor on or near the suspect area outside the vehicle.
f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another
reading.
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g. Compare the readings.
- A match in frequency indicates the problem component or area.
- An unmatched test could indicate the concern is caused by the engine, torque converter, or
engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
- Example: A vibration is felt in the seat, place the sensor on the console. Record the readings.
Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same,
the axle is the problem component. Also refer to the following chart as a reference to acceptable
vibration and noise ranges for the specified components.
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in
pinpointing the source of unacceptable vibrations. The
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engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will
have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate
software® calculates the angular velocity of each component and graphically represents these
velocities on a computer screen and on a printed vibration worksheet. The following steps outline
how Vibrate software® helps diagnose a vibration concern:
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
- An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be
needed.
^ Provides pictures of diagnostic procedures to aid in testing components.
ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The chassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier
bearings.
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect
the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power
steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear
teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones.
The directional sensing tip is used to listen to the various components. Point the sensing tip at the
suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and vibrations, generated by or passing through, the
component. Various volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas
where there is weather-stripping or other sealing material. It is also used to identify A/C leaks,
vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a
multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The
transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is
used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping
sound is produced which increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to
eliminate interior and exterior squeaks and rattles. The kit consists of the following materials:
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube
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^ Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is
1-800-822-4100. Carry out the tracing powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only.
c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal.
Gaps or a faint imprint will show where there is poor contact with the weatherstrip.
Dollar bill or 3x5 Card
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Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the
door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure
on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card
is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates
insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is
out of alignment.
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
Special Service Tool(s)
Diagnostic Process
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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide
are included with this material. The Write-up Job Aid serves as a place to record all important
symptom information. The NVH Diagnostic Guide serves as a place to record information reported
on the Write-up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings,
then proceed to each of the numbered process steps to complete the diagnosis.
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as
much information as possible about the problem and take a test drive with the customer. There are
many ways a customer will describe NVH concerns and this will help minimize confusion arising
from descriptive language differences. It is important that the concern is correctly interpreted and
the customer descriptions are recorded. During the interview, ask the following questions:
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^ When was it first noticed?
^ Did it appear suddenly or gradually?
^ Did any abnormal occurrence coincide with or proceed it's appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2. Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments
before taking the vehicle on the road.
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
^ Remember that the vibrating source component (originator) may only generate a small vibration.
This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path).
^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4. Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test, or both.
The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is
sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always
be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried
out correctly.
5. Road Test
Note:
It may be necessary to have the customer ride along or drive the vehicle to point out the concern.
During the road test. take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding
to the next step of this process.
^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
^ The Heavy Acceleration Test helps to determine if the concern is torque-related.
^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
^ The Downshift Speed Test helps to determine if the concern is engine speed-related.
^ The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related concern.
^ The Brake Test helps to identify vibrations or noise that are brake related.
^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These
tests help to determine if the concern is engine
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speed-related.
^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the
concern occurs at idle.
^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the
Neutral Run-up Test or the Neutral Coast Down Test.
^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed-related concerns.
^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
^ Attempt to identify from what part of the vehicle the concern is coming.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
^ Accelerate hard from 0-64 km/h (0-40 mph).
^ Decelerate in a lower gear.
^ The concern is torque related if duplicated while carrying out this test.
^ Proceed as necessary.
Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test
to verify if the concern is engine speed related.
^ Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
^ Drive at the engine rpm where the concern occurs.
^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.
^ Proceed as necessary.
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Steering Input Test
To carry out this test, proceed as follows:
^ Drive at the speed where the concern occurs, while making sweeping turns in both directions.
^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
^ Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light
pedal force.
^ Accelerate to 89-97 km/h (55-60 mph).
^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is release.
Road Test Over Bumps
To carry out this test, proceed as follows:
^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
^ Proceed as necessary.
Neutral Engine Run-up (NERU) Test
To carry out this test, proceed as follows:
^ In stall a tachometer.
^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel
drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine
rpm and, if possible, determine the vibration frequency.
^ Attempt to identify what part of the vehicle the concern is coming from.
^ Attempt to identify the source of the concern.
^ Proceed as necessary.
Drive Engine Run-up (DERU) Load Test
To carry out this test, proceed as follows:
^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or
transaxle can result.
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.
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^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
^ Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to
personnel can result.
CAUTION:
Limit engine running time to one minute or less with belts removed or serious engine damage will
result.
Note:
A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration
analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as
an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
^ Increase the engine mm to where the concern occurs.
^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not
sources.
^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
^ Test preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for
up to three minutes.
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6-~ hours.
^ Before starting the engine, conduct a visual inspection under the hood.
^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system
(ABS) and air suspension system noises.
^ Start the engine.
^ CAUTION:
Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6. Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history
for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern.
Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This
diagnostic method divides the problem into related areas to correct the customer concern.
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^ Verify the "symptom".
^ Determine which "system(s)" can cause the "symptom".
- If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft
frequency should be calculated.
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing
frequencies should be calculated.
^ After determining the "system", use the diagnostic tools to identify the worn or damaged
'components".
^ After identifying the "components". try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and
Symptom Categories.
Operating Condition - Vehicle Is Not Moving
1. Static operation
^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle.
2. While cranking
1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak
and Rattle.
3. Vibration. Acceptable condition.
3. At idle
^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration.
^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration.
4. During Gear Selection
1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration.
3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
Operating Condition - Vehicle Is Moving
1. Depends more on how the vehicle is operated
1. Speed related
^ Related to vehicle speed
- Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration.
- Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration.
- Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness
increase with speed. GO to Symptom Chart - Driveline Noise/Vibration.
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- A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to
Symptom Chart Tire Noise/Vibration.
- Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise.
^ Related to engine speed.
- Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration.
- Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).
2. Acceleration
^ Wide open throttle (WOT)
- Engine induced contact between components. Inspect and repair as necessary.
- Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom
Chart - Engine Noise/Vibration.
^ Light/moderate acceleration
- Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration.
- Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration.
- Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration.
- Engine vibration. GO to Symptom Chart - Engine Noise/Vibration.
3. Turning noise. GO to Symptom Chart
- Steering Noise/Vibration.
4. Braking.
^ Clicking sound is signaling ABS is active. Acceptable ABS sound.
^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration.
^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration.
5. Clutching
^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and
Transfer Case Noise/Vibration.
^ Vibration. GO to Symptom Chart -
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Transmission (Manual) and Transfer Case Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration.
^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission
(Manual) and Transfer Case Noise/Vibration.
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case
Noise/Vibration.
8. Cruising speeds
^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration.
^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration.
^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration.
9. Driving at low/medium speeds
^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration.
^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak
and Rattle.
^ Noise or vibration changes from one road surface to another. Normal sound changes.
^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension
Noise/Vibration.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7097
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7098
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7099
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7101
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7102
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7103
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7104
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a
condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only
the steps necessary to correct the condition. Then, test the system for normal operation.
Sometimes, it is necessary to remove various vehicle components to gain access to the component
requiring testing. For additional information, REFER to the appropriate Workshop Manual section
for removal and installation procedures. Reinstall all components after verifying system operation is
normal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7105
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7106
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7107
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7108
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7109
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7110
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7111
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7112
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7113
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7114
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7115
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7116
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7117
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7118
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7119
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7121
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7122
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7123
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7125
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7126
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7127
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7128
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7129
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7130
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7131
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7132
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7133
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7134
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7135
Idle Speed Air Control Valve (ISACV)
1. Open the hood.
2. Note:
Key symptom is elevated idle speed while noise is occurring.
Note:
"Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV.
4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet
tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean
air tube. If the ISACV is making the noise, install a new ISACV.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3.
CAUTION:
Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Damage to the power steering pump will occur.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7136
Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system
condition.
Checking Tooth Contact Pattern/Condition of Ring & Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range. The second type of ring and pinion noise
pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces
a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch.
1. Raise and support the vehicle.
2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the
appropriate workshop manual for the service procedures.
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe.
There should always he some clearance between the contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The high contact pattern indicates that the drive pinion is not installed deep enough into the
carrier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7137
^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease
will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier.
^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel.
^ Tooth contact pattern shown on the drive side of the gear teeth.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7138
^ The pinion gear depth is correct. Decrease the differential ring gear backlash.
Tire Wear Patterns & Frequency Calculations
Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more
than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the
transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel
vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt
in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a
concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be
caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and
wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the
tire wear chart to determine the tire wear conditions and actions.
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm.
Calculate tire and wheel rpm and frequency by carrying out and following:
^ Measure the diameter of the tire.
^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and
frequency from the Tire Speed and Frequency Chart.
- If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16
(km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in
the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in)
tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at
40mph.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7139
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7140
Powertrain/Drivetrain Mount Neutralizing
WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION:
Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Exhaust System Neutralizing
WARNING:
Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair
exhaust system leaks immediately. Never operate the engine in an enclosed area.
WARNING:
Exhaust system components are hot.
Note:
Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7141
CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he
the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket
free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint
last).
^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure
that the catalytic converter and heat shield do not contact the frame rails.
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
^ With the exhaust system installed securely and cooled. the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
Wheel Bearing Check
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise the vehicle until the front tires are off the floor.
^ Make sure the wheels are in a straight forward position.
2. Note:
Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free
movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7142
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop
manual for the service procedures.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 7143
Wheel Bearing: Service Precautions
CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the
improper grease can cause bearing damage.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 7144
Wheel Bearing: Testing and Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new
wheel hub.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 7145
Wheel Bearing: Service and Repair
FRONT WHEEL HUB
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. Remove and discard the front hub cap grease seal.
5. CAUTION: The front axle wheel hub retainer must never be reused. If the retainer is reused, it
can back off resulting in loss of the front
wheel and or damage to the wheel hub and bearing assembly.
Remove the front axle wheel hub retainer. Discard the retainer.
6. CAUTION: When removing the wheel hub and bearing, use caution not to damage the ABS
sensor lead or the ABS sensor ring.
NOTE: The wheel hub and bearing assembly is a slip fit design and should not require a puller to
remove.
Remove the wheel hub and bearing assembly.
Installation
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 7146
1. CAUTION: When installing the wheel hub and bearing, use extreme caution not to damage the
ABS sensor lead or the ABS sensor ring.
Install the wheel hub and bearing assembly.
2. Install a new front axle wheel hub retainer.
3. Install a new front hub cap grease seal. 4. Install the brake disc. 5. Install the wheel and tire
assembly. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Front Axle Wheel Hub Retainer
...........................................................................................................................................................
300 Nm (221 ft. lbs.)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake roughness, shudder and vibration.
Tighten the lug nuts to 115-142 Nm (85-105 ft. lbs.) in a star-pattern sequence.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front
Wheel Fastener: Service and Repair Front
Special Tools
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake
disc.
4. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage
the ABS sensor lead or the ABS sensor
ring.
Using the special tool, press the wheel stud out of the wheel hub and bearing flange.
Installation
1. CAUTION: When removing and installing the wheel studs, use extreme caution not to damage
the ABS sensor lead or the ABS sensor
ring.
Position the wheel stud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7156
2. Install the wheel stud.
1 Install four washers onto the wheel stud.
2 Install reversed wheel nut. Tighten the wheel nut until the wheel stud seats fully onto the wheel
hub and bearing flange.
3. Remove the wheel nut and washers. 4. Install the brake disc. 5. Install the wheel and tire
assembly. 6. Lower the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7157
Wheel Fastener: Service and Repair Rear
Special Tools
Removal
Special Tools
1. WARNING: The electrical power to the air suspension system must be turned off prior to
hoisting, jacking or towing an air suspension
vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Turn the air suspension service switch off (If equipped).
2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. Remove rear brake
disc.
5. Using the special tool, press the lug bolt from its seat and discard.
Installation
CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7158
1. Insert a new lug bolt in the hole in the axle flange, making sure serrations are aligned with those
in the flange.
2. Place four flat washers over the outside end of the lug bolt, and thread a standard lug nut with
the flat side against the washers. 3. Tighten the lug nut until the lug bolt head seats against the
back side of the axle flange. 4. Remove the lug nut and washers. 5. Install the rear brake disc. 6.
Install the wheel and tire assembly. 7. Lower the vehicle.
8. Turn the air suspension service switch on (If equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Page 7159
Wheel Fastener: Tools and Equipment
Special Tool
Special Tool
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications
Accumulator HVAC: Specifications
Accumulator Mounting Bracket Clamp Bolt
....................................................................................................................................... 6-8 N.m
(54-70 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 7164
Accumulator HVAC: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The suction accumulator/drier is mounted to the right of the vehicle centerline. The inlet tube of the
suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet
tube of the suction accumulator/drier attaches to the evaporator to compressor suction line.
After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an
internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the
canister.
- A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated
heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate.
- As the heavier mixture passes through the small diameter liquid bleed hole, it has a second
chance to vaporize and recirculate through the A/C compressor without causing compressor
damage due to slugging.
- A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out
refrigerant system contaminant particles.
- A desiccant bag is mounted inside the canister to absorb any moisture which may be in the
refrigerant system.
- A fitting located on the side of the suction accumulator/drier is used to mount a serviceable
low-pressure A/C charge port valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 7165
Accumulator HVAC: Service and Repair
REMOVAL
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
1. Recover the refrigerant.
2. Disconnect the evaporator to compressor suction line from the suction accumulator/drier.
3. Disconnect the suction accumulator/drier from the A/C evaporator core.
CAUTION: To prevent damage to the fitting and the tube, use a backup wrench when removing the
suction accumulator/drier.
4. Remove the screw retaining the A/C accumulator mounting bracket to the A/C evaporator core
and remove the suction accumulator/drier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 7166
5. Remove the insulation cover from the suction accumulator/drier.
6. Remove the A/C accumulator mounting bracket from the suction accumulator/drier.
INSTALLATION
1. To install, reverse the removal procedure.
- Service the new suction accumulator/drier with the correct amount of PAG compressor oil
YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
CAUTION: To prevent damage to the fitting and the tube, use a backup wrench when installing the
suction accumulator/drier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams
Air Door Actuator / Motor: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Description and Operation > Air Door Actuator
Air Door Actuator / Motor: Description and Operation Air Door Actuator
Vacuum Control Motors
Vacuum control motors for the Manual A/C system operate the same as the EATC system.
With Electronic Automatic Temperature Control
Vacuum control motors are used to move the floor/panel and panel/defrost doors.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Description and Operation > Air Door Actuator > Page 7173
Air Door Actuator / Motor: Description and Operation Blend Door Motor
With Electronic Automatic Temperature Control
The A/C electronic blend door actuator is located on the top of the plenum housing.
- Its function is to move the air temperature blend door on command from the control assembly.
- The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer.
The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft
to indicate the position of the air temperature blend door.
- A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper
indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is
sent to the electronic automatic temperature control module and is matched with the wiper voltage
of the module potentiometer. The control module then drives the actuator motor in the direction
necessary to make the actuator wiper voltage agree with the control module wiper voltage.
With Manual A/C
The Electronic Blend Door Actuator for the manual A/C system function is similar to the EATC
system, except that the temperature potentiometer is controlled by the knob located in the center of
the A/C manual control.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Air Door Actuator
Air Door Actuator / Motor: Service and Repair Air Door Actuator
Air Recirculation Door
REMOVAL
1. Remove the pin-type connectors and retainer and remove the instrument panel lower insulator.
2. Disconnect the vacuum connector.
3. Remove the control arm clip and the spring.
4. Remove the nuts and remove the vacuum control motor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Air Door Actuator > Page 7176
INSTALLATION
1. To install, reverse the removal procedure.
Floor Duct Door
REMOVAL
1. Remove the plenum chamber.
2. Reach through the door opening and remove the pin.
3. Remove the screws and remove the vacuum control motor.
INSTALLATION
1. To install, reverse the removal procedure.
Windshield Defrost Door
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the LH lower dash insulator panel and disconnect the lamp.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Air Door Actuator > Page 7177
3. Remove the two pin-type connectors and remove the fill panel.
4. Remove the screws.
5. Disengage the vacuum line.
6. Remove the lighting module.
1 Remove the screws.
2 Disengage the clip.
3 Remove the lighting module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Air Door Actuator > Page 7178
7. Remove the connectors.
8. Remove the screws and remove the bracket.
9. Remove the vacuum motor.
1 Remove the clip.
2 Remove the nuts.
3 Remove the vacuum motor.
10. Disconnect the vacuum lines and remove the vacuum motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Air Door Actuator > Page 7179
Air Door Actuator / Motor: Service and Repair Blend Door Motor
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the instrument panel.
3. Disconnect the connector.
4. Remove the four screws.
5. Remove the electronic blend door actuator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct
Air Duct: Service and Repair A/C Recirculating Air/Air Inlet Duct
REMOVAL
1. Remove the instrument panel. 2. Remove the plenum chamber. 3. Remove the RH front wheel
and tire.
4. Remove the bolts and reposition the fender apron.
5. Remove the bolt.
6. Remove the screws and the pin-type retainer and reposition the cowl top cover to access the
duct nut.
7. Remove the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7184
8. Remove the nut and position the harness cover aside.
9. Remove the nut.
10. Remove the bolt.
11. Remove the wiring harness.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7185
12. Disengage the connectors and remove the air recirculating duct.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7186
Air Duct: Service and Repair Instrument Panel Ducts
DISASSEMBLY
1. Remove the instrument panel.
2. Remove the screw and remove the bracket.
3. Disengage the in-car temperature sensor hose retainers.
4. Remove the screws.
5. Remove the RH panel duct.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7187
6. Remove the screws and the RH demister nozzle.
7. Remove the screws and the LH demister nozzle.
8. Disengage the radio antenna.
9. Remove the screws retaining the LH panel duct to the defroster duct, but do not remove the
duct.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7188
10. Remove the screws and remove the defroster duct. 11. Remove the LH panel duct.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7189
Air Duct: Service and Repair Rear Seat Air Flow
REMOVAL
1. Remove the seats. 2. Remove the carpet.
3. Remove the pin-type retainer on each side of the duct and remove the duct.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C
Recirculating Air/Air Inlet Duct > Page 7190
Air Duct: Service and Repair Removal and Installation
REMOVAL
1. Remove the rear seat airflow duct. 2. Remove the steering column lower cover.
3. Remove the vacuum motor screws.
4. Remove the heater outlet floor duct.
1 Position the vacuum motor aside.
2 Remove the screws.
3 Remove the heater outlet floor duct.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Left and Center
Air Register: Service and Repair Left and Center
Radio Removal Tool
Special Tool(S)
REMOVAL
1. Use the Radio Removing Tool to remove the radio chassis.
2. Disconnect the antenna lead and the wire harness connectors.
3. Remove the 8 screws and remove the finish panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Left and Center > Page 7195
4. Disconnect the connector, each side of steering column.
5. Disconnect the headlight and dimmer switch wire harness connectors.
6. Disengage the four lock tabs and remove the register assemblies.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Left and Center > Page 7196
Air Register: Service and Repair Right
REMOVAL
1. Remove the passenger side airbag.
2. Remove the screw and the RH instrument panel register.
3. Disengage the lock tabs and remove the register assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Page 7197
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Air Temperature Sensor <--> [Ambient Temperature
Sensor / Switch HVAC] > Component Information > Description and Operation
Ambient Air Temperature Sensor: Description and Operation
The A/C ambient air temperature sensor and bracket:
- is located in front of the A/C condenser core near the center of the vehicle.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the electronic automatic temperature control assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Air Temperature Sensor <--> [Ambient Temperature
Sensor / Switch HVAC] > Component Information > Description and Operation > Page 7201
Ambient Air Temperature Sensor: Service and Repair
REMOVAL
1. Remove the radiator upper sight shield.
2. Disconnect the wire harness connector.
3. Remove the A/C ambient air temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and
Operation
Blower Motor: Description and Operation
The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is
mixed and distributed.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and
Operation > Page 7205
Blower Motor: Service and Repair
REMOVAL
1. Disengage the wire harness connectors from the retainer.
2. Disconnect the wire harness connector.
3. Remove the hose.
4. Remove the screws and remove the blower motor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and
Operation > Page 7206
5. Remove the wheel from the blower motor.
1 Remove the push clip.
2 Remove the wheel from the blower motor.
CAUTION: Prior to removing a wheel that is to be reused, clean any corrosion from the blower
motor shaft to prevent damage to the wheel mounting shaft.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description
and Operation
Blower Motor Resistor: Description and Operation
The heater blower motor switch resistor has the following features:
- The assembly is located in the engine compartment on the evaporator housing toward the center
of the vehicle.
- Three resistor elements are mounted on the resistor board to provide four blower motor speeds.
- Depending on the heater blower motor switch position, series resistance is added or bypassed in
the A/C blower motor circuit to decrease or increase A/C blower motor speed.
- An overheating protective device (thermal limiter) will open the resistor coil when the temperature
reaches 121°C (250°F). interrupting the blower motor operation in all speeds except HI.
- The thermal limiter cannot be reset and is not serviceable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
This model is not equipped with a cabin air filter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > In-Car Temperature Sensor <--> [Cabin Temperature Sensor /
Switch] > Component Information > Description and Operation
In-Car Temperature Sensor: Description and Operation
The in-car temperature sensor operates in the following manner:
- A thermistor in the in-car temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the A/C
evaporator housing and the in-car temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the A/C evaporator
housing air stream to create a suction in the in-car temperature sensor.
- The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > In-Car Temperature Sensor <--> [Cabin Temperature Sensor /
Switch] > Component Information > Description and Operation > Page 7216
In-Car Temperature Sensor: Service and Repair
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the screws and pull the control assembly away from the instrument panel.
4. Remove the screws and position the in-car temperature sensor to access the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > In-Car Temperature Sensor <--> [Cabin Temperature Sensor /
Switch] > Component Information > Description and Operation > Page 7217
5. Disconnect the connector.
6. Disconnect the hose and remove the in-car temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Clutch Air Gap and Runout
Compressor Clutch: Specifications Clutch Air Gap and Runout
MAGNETIC CLUTCH
Air Gap Between Pulley and Hub
................................................................................................................. 0.35 mm - 0.85 mm (0.014
- 0.033 inch)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Clutch Air Gap and Runout > Page 7223
Compressor Clutch: Specifications Torque
A/C Compressor Clutch Retaining Bolt
........................................................................................................................................ 11-14 N.m
(98-123 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7224
Compressor Clutch: Adjustments
1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C
clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the
compressor shaft until clearance is within specifications.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <-->
[Compressor Clutch Coil] > Component Information > Service and Repair
A/C Compressor Clutch Coil: Service and Repair
Special Tool(S)
REMOVAL
1. Remove the A/C compressor.
2. Remove the bolt.
1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool.
2 Remove the bolt.
3. Remove the A/C clutch and the A/C clutch hub spacer.
1 Thread an 8 x 1.25 mm bolt into the A/C clutch hub spacer to force it from the compressor shaft.
2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <-->
[Compressor Clutch Coil] > Component Information > Service and Repair > Page 7228
4. Remove the pulley snap ring.
5. Remove the A/C clutch pulley.
6. Remove the A/C clutch field coil.
1 Note the location of the A/C clutch field coil electrical connector.
2 Install the Field Coil Remover on the nose opening of the A/C compressor.
3 Install the Puller - Differential Bearing Cone Remover.
4 Remove the A/C clutch field coil.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
INSTALLATION
1. Clean the A/C clutch field coil and pulley mounting surfaces.
2. Install the A/C clutch field coil.
1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical
connector correctly positioned.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <-->
[Compressor Clutch Coil] > Component Information > Service and Repair > Page 7229
2 Place the Field Coil Replacer on the A/C clutch field coil. Place the Coil Replacer on the Field
Coil Replacer.
3 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C
compressor.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
3. Install the A/C clutch pulley.
NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned
during installation.
4. Install the pulley snap ring with the bevel side out.
5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.
6. Install the A/C clutch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <-->
[Compressor Clutch Coil] > Component Information > Service and Repair > Page 7230
7. Install the bolt.
1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool.
2 Tighten the bolt.
8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install
the A/C compressor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Coil <-->
[Compressor Clutch Coil] > Component Information > Service and Repair > Page 7231
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair
Compressor Shaft Seal: Service and Repair
Special Tool(S)
REMOVAL
1. Remove the A/C clutch from the A/C compressor.
2. Remove the shaft seal felt from the nose of the A/C compressor with the O-ring Remover. 3.
Clean the compressor nose area.
4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > Page 7235
5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C
compressor shaft.
6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose
opening and remove the snap ring.
7. Engage the Compressor Remover into the inside diameter of the shaft seal.
8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > Page 7236
9. Pull the seal from the A/C compressor.
INSTALLATION
1. Clean the A/C compressor nose area.
CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials
to enter the A/C compressor.
2. Place the shaft seal on the Seal Protector. Lubricate the shaft seal and the Seal Protector with
PAG compressor oil YN-12-C F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B.
3. Position the shaft seal and the Seal Protector over the A/C compressor shaft.
4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Installer until seated.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > Page 7237
5. Install the shaft seal snap ring with the sharp edge facing up. 6. Carry out the A/C compressor
external leak test.
7. Install the shaft seal felt. 8. Install the A/C clutch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > Page 7238
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7242
Compressor Clutch Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7243
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications
Compressor Fitting HVAC: Specifications
A/C Manifold And Tube Retaining Bolt
......................................................................................................................................... 18-24 N.m
(14-17 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 7247
Compressor Fitting HVAC: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Recover the refrigerant.
3. Remove the A/C compressor to condenser discharge line nut.
4. Disconnect the A/C compressor to condenser discharge line from the A/C manifold and tube.
5. Disconnect the evaporator to compressor suction line from the A/C manifold and tube.
6. Loosen the bolt and remove the A/C manifold and tube.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 7248
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
- Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification
WSK-M2G350-A2 to the threads of the A/C manifold bolt.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications
Condenser HVAC: Specifications
A/C Condenser Core Mounting Bolts
............................................................................................................................................... 8-11
N.m (71-97 Lb-In) Compressor To Condenser Tube Bracket Retaining Nut
................................................................................................................ 17-23 N.m (13-16 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 7252
Condenser HVAC: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The A/C condenser core has the following characteristics:
- It 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.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 7253
Condenser HVAC: Testing and Inspection
ON-VEHICLE LEAK TEST
1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core from the
air conditioning system.
NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the
core tubes.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R12-/R134-a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red
and blue hoses from the R134-a Manifold Gauge Set to the test fittings on the A/C evaporator core
or A/C condenser core.
Connect the yellow hose to a known good vacuum pump.
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 which will
activate the valve. The test is not valid if the shut-off valve does not open.
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 A/C evaporator core or A/C 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 A/C evaporator core or A/C 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 A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 7254
Condenser HVAC: Service and Repair
REMOVAL
NOTE:
- If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it
is removed from the vehicle.
- Installation of a new suction accumulator/drier is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator/drier.
1. Recover the refrigerant. 2. Remove the battery.
3. Remove the radiator upper sight shield.
4. Disconnect the condenser to evaporator tube from the A/C condenser core.
5. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 7255
6. Remove the bolts and remove the radiator supports.
7. Remove the two bolts.
8. Tilt the radiator back and lift out the A/C condenser core.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 7256
1. To install, reverse the removal procedure.
- Service the new A/C condenser core with the correct amount of PAG compressor oil YN-12-C
F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation
Control Assembly: Description and Operation
The climate control assembly has three system controls:
- The A/C heater function selector switch combines a vacuum selector valve with two electrical
switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control
circuit.
- Temperature selection is accomplished with a potentiometer connected to the electric blend door.
Movement of the control knob from COOL (Blue) to WARM (Red) causes a corresponding
movement on the air temperature blend door and determines the temperature that the system will
maintain.
- The blower motor switch controls blower motor speed by adding or bypassing resistors in the
heater blower motor switch resitor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Switches
Control Assembly: Service and Repair Climate Control Switches
REMOVAL
1. Remove the control assembly.
2. Remove the function selector.
1 Depress the snap tabs.
2 Remove the function selector.
NOTE: The knob will drop off as the function selector is removed.
3. Remove the temperature blend control switch.
1 Remove the screw.
2 Rotate and pull the temperature blend control switch.
NOTE: The knob will drop off as the temperature blend control switch is removed.
4. Remove the blower motor switch.
1 Depress the snap tabs.
2 Remove the blower motor switch.
NOTE: The knob will drop off as the blower motor switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Switches > Page 7262
Control Assembly: Service and Repair With Manual A/C
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the climate control head.
1 Remove the screws.
2 Remove the climate control head.
4. Disconnect the climate control head.
- Disconnect the electrical connectors.
- Disconnect the vacuum line connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Switches > Page 7263
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Climate Control - Blower Control Service Tips > Page 7268
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Climate Control - Blower Control Service Tips > Page 7269
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Blower Motor Speed Control
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Blower Motor Speed Control > Page 7272
Control Module HVAC: Diagrams Electronic Climate Control Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description
and Operation > Blower Motor Speed Control
Control Module HVAC: Description and Operation Blower Motor Speed Control
The A/C blower motor speed control is located on the A/C evaporator housing, in the engine
compartment.
- The function of the A/C blower motor speed control is to convert low power signals from the
electronic automatic temperature control module to a high current, variable ground feed for the
blower motor.
- Blower motor speed is infinitely variable and is controlled by the electronic automatic temperature
control module software.
- A delay function provides a gradual increase or decrease in blower motor speed under all
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description
and Operation > Blower Motor Speed Control > Page 7275
Control Module HVAC: Description and Operation Electronic Climate Control Module
The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel,
has the following features:
- a blower speed override control for manual input
- a vacuum fluorescent display for displaying set temperature, ambient temperature, function and
Diagnostic Trouble Codes (DTCs)
- an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes
(DTCs). These DTCs direct the technician to the inoperative component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and
Repair > Blower Motor Speed Control
Control Module HVAC: Service and Repair Blower Motor Speed Control
REMOVAL
1. Disconnect the wire harness connector. 2. Drain the cooling system below the heater hoses.
3. Disconnect the heater hose.
4. Remove the screws and remove the blower motor speed control.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and
Repair > Blower Motor Speed Control > Page 7278
Control Module HVAC: Service and Repair Electronic Climate Control Module
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the screws and pull the Electronic Automatic Temperature Control (EATC) module from
the instrument panel.
4. Remove the EATC module.
- Remove the nuts and the vacuum harness.
- Disconnect the wire harness connectors and remove the EATC module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and
Repair > Blower Motor Speed Control > Page 7279
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications
Coupler HVAC: Specifications
Peanut Fitting Nut ................................................................................................................................
............................................... 7-9 N.m (62-79 Lb-In) Peanut Fitting Retaining Nut ............................
................................................................................................................................... 7-9 N.m (62-79
Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and
Operation > Peanut Fitting
Coupler HVAC: Description and Operation Peanut Fitting
The A/C condenser core uses the peanut-shaped refrigerant fittings instead of spring lock
couplings.
- The male and female blocks of the peanut fitting are retained with a nut.
- An O-ring seal is installed around the tube on the male block.
- The female block is welded to the tube and is not adjustable.
- Support the female fitting with a wrench to prevent twisting of the tubes.
- The male block will pivot around the tube to allow for alignment with the female block during
assembly.
- When properly assembled the male and female fittings should be flush.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and
Operation > Peanut Fitting > Page 7285
Coupler HVAC: Description and Operation Spring Lock Coupling
Spring Lock Coupling
The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a
circular cage.
- When the coupling is connected together, the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
- The garter spring and cage then prevent the flared end of the female fitting from pulling out of the
cage.
- Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings,
all other couplings have two O-ring seals.
- These O-ring seals are green in color and are made of special material.
- Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock
coupling.
- A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate,
during vehicle assembly, that the coupling is connected. Once the coupling is connected, the
indicator ring is no longer necessary but will remain captive by the coupling near the cage opening.
- The indicator ring may also be used during service operations to indicate connection of the
coupling.
- An A/C tube lock coupling clip may be used to secure the coupling but is not required.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Peanut Fitting
Coupler HVAC: Service and Repair Peanut Fitting
DISCONNECT
1. Remove the nut from the peanut fitting.
CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting.
2. Pull the peanut fitting apart.
3. Remove the O-ring seal with a non-metallic tool.
CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches
across the O-ring seal groove resulting in refrigerant leaks.
CONNECT
1. Clean all dirt or foreign material from the fittings.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Peanut Fitting > Page 7288
2. Install the O-ring seal.
- Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B.
CAUTION: Use only new green O-rings seals. The use of any O-ring seals other than specified
may result in intermittent leakage during vehicle operation.
3. Lubricate the inside of the fittings with PAG Compressor Oil F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
4. Assemble the male and female fittings together.
NOTE: When correctly assembled the male and female fittings should be flush.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Peanut Fitting > Page 7289
Coupler HVAC: Service and Repair Spring Lock Coupling
Spring Lock Coupling Disconnect Tool Set
Special Tool(S)
DISCONNECT
1. Disconnect the A/C tube lock coupling clip.
2. Fit the spring lock coupling disconnect tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the A/C tube look coupling
spring.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Peanut Fitting > Page 7290
4. Pull the spring lock coupling fittings apart.
5. Remove the O-ring seals with a non-metallic tool.
CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches
across the O-ring seal grooves resulting in refrigerant leaks.
6. Remove the A/C tube lock coupling spring with a small hooked wire.
CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring;
this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks.
CLEANING
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from
maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size.
Coupling Size Pad Size
3/8 inch 25 x 50 mm (1 x 2 inch)
1/2 inch 25 x 50 mm (1 x 2 inch)
5/8 inch 25 x 76 mm (1 x 3 inch)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Peanut Fitting > Page 7291
3/4 inch 25 x 102 mm (1 x 4 inch)
3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Compressor Oil
F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the
tool and install it in a variable speed drill motor.
6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and
free of scratches or foreign material.
CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent
axial scratches which may cause future leaks.
7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves
and scratches are still present, install a new component.
9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string.
- Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint-free cloth.
CONNECT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Peanut Fitting > Page 7292
1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Compressor Oil F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
3. Install the O-ring seals.
- Lubricate the O-ring seals with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B.
CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may
resuit in intermittent leakage during vehicle operation.
4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling
spring snaps over the flared end of the female
fitting.
5. Install the A/C tube lock coupling clip.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
Evaporator Case: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Drain the radiator so that the
coolant level is below the heater core. 4. Raise the vehicle. 5. Remove the RH front wheel and tire.
6. Remove the screws from the RH fender apron and remove the fender apron.
7. Remove the nuts. 8. Lower the vehicle. 9. Remove the blower motor switch resistor.
10. Disconnect the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7296
11. Disconnect the evaporator to compressor suction line from the suction accumulator drier.
12. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube.
13. Remove the nuts and position the purge valve and bracket away from the evaporator core
housing.
14. Remove the heater hoses from the heater core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7297
15. Disengage the connectors from the bracket.
16. Disconnect the connector.
17. Remove the nut and reposition the wire harness away from the evaporator housing.
18. Disengage the harness from the bracket.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7298
19. Remove the pin-type retainer and clip and remove the instrument panel lower insulator.
20. Fold back the carpet and remove the screw.
21. Inside the vehicle, remove the screw.
22. Remove the nuts (engine side).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7299
23. Remove the in-car temperature sensor hose and elbow from the evaporator housing (if
equipped).
24. Remove the evaporator housing.
INSTALLATION
1. Position the evaporator core housing on the dash panel.
2. Install the in car temperature sensor hose.
3. Install the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7300
4. Install the screw.
5. Install the screw.
6. Install the RH lower instrument panel insulator. 7. Raise the vehicle.
8. Install the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7301
9. Position fender apron and install the bolts.
10. Install the front wheel and tire. 11. Lower the vehicle.
12. Connect the connector.
13. Install the connectors.
14. Install the wire harness push connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7302
15. Position harness and install the nut.
16. Install the nuts.
17. Install the heater hoses.
- Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or
equivalent meeting Ford specification ESF-M99B112-A.
18. Connect the evaporator compressor suction line to the suction accumulator/drier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 7303
19. Connect the condenser to evaporator tube.
20. Connect the connector. 21. Install the blower motor switch resistor. 22. Connect the battery
ground cable. 23. Fill the cooling system. 24. Evacuate and recharge the refrigerant system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation
Evaporator Core: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The A/C evaporator core is the plate/fin type with a unique refrigerant flow path.
- A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C
evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin
sections.
- The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end
of the A/C evaporator core.
- Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the
A/C evaporator core through the A/C evaporator core outlet tube.
- This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator
core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7307
Evaporator Core: Testing and Inspection
ON-VEHICLE LEAK TEST
1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core from the
air conditioning system.
NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the
core tubes.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R12-/R134-a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red
and blue hoses from the R134-a Manifold Gauge Set to the test fittings on the A/C evaporator core
or A/C condenser core.
Connect the yellow hose to a known good vacuum pump.
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 which will
activate the valve. The test is not valid if the shut-off valve does not open.
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 A/C evaporator core or A/C 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 A/C evaporator core or A/C 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 A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7308
Evaporator Core: Service and Repair
REMOVAL
NOTE:
- Installation of a new suction accumulator/drier is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator/drier.
- If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it
is removed from the vehicle.
1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Remove the A/C evaporator
core housing.
4. Remove the six screws.
5. Carefully cut the seal in two places and separate the two halves of the evaporator housing.
6. Disconnect the suction accumulator/drier from the evaporator core outlet tube.
CAUTION: To prevent damage to the fitting and tube, always use a backup wrench when removing
the suction accumulator/drier.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7309
7. Remove the screws and remove the suction accumulator/drier.
8. Remove the A/C evaporator core.
INSTALLATION
1. To install, reverse the removal procedure.
- Service the new A/C evaporator core with the correct amount of PAG compressor oil YN-12-C
F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component
Information > Specifications
Orifice Tube: Specifications
Color Code ..........................................................................................................................................
........................................................................ Orange Orifice Diameter .............................................
........................................................................................................................................ 1.46 mm
(0.0575 in)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component
Information > Specifications > Page 7313
Orifice Tube: Description and Operation
NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is
installed.
The A/C evaporator core orifice has the following characteristics:
- It is located in the A/C evaporator core inlet tube.
- It has filter screens located on the inlet and outlet ends of the tube body.
- The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C
evaporator core orifice.
- O-ring seals on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from
bypassing the A/C evaporator core orifice.
- Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be
installed as a unit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component
Information > Specifications > Page 7314
Orifice Tube: Service and Repair
Special Tool(S)
REMOVAL
1. Remove the condenser to evaporator tube.
- For a fixed orifice tube, perform Steps 2 and 3.
- For a broken orifice tube, perform Steps 4 and 5.
2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice.
3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core
orifice.
4. Screw the end of the Broken Orifice Extractor into the broken A/C evaporator core orifice.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component
Information > Specifications > Page 7315
5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator
core orifice.
INSTALLATION
1. Lubricate and install the O-ring seals on the A/C evaporator core orifice.
- Use PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification
WSH-M1C231-B.
2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool.
3. Insert the A/C evaporator core orifice into the tube end until seated.
4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component
Information > Specifications > Page 7316
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7325
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7326
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7332
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7333
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Core: > 99-2-3 > Feb > 99 > Windshield - Water Leaks
Windshield: All Technical Service Bulletins Windshield - Water Leaks
Article No. 99-2-3
^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP
^ WINDSHIELD - SEALING - SERVICE TIP
FORD: 1995-97 PROBE, THUNDERBIRD
1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND
MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER
LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER,
F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION,
MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or
a void in the production sealer somewhere around the periphery of the windshield.
ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the
periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip
removal where necessary.
NOTE
DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY
BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO
ENSURE REPAIR OF THE LEAK.
The following is the labor operation to be used for this repair and a chart providing Windshield
Sealing Labor Times:
^ 03100B
PART NUMBER PART NAME
F8AZ-19554-CA Liquid Butyl Sealer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Core: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 7339
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 110000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Core: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 7345
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 110000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7346
Heater Core: Specifications
Rubber Suspension Insulator Lube E25Y-19553-A
....................................................................................................................................
ESF-M99B112-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7347
Heater Core: Description and Operation
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7348
Heater Core: Testing and Inspection
WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate
the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to
vent the exhaust gases outside the closed area. Failure to follow these instructions may result in
personal injury.
1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good
and a new heater core was not required. 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.
2. Check the integrity of the heater water hose clamps.
NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at the heater water hose connection and damage the
heater core.
Heater Core-Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is working
correctly.
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, feel the heater core outlet hose
to see if it is hot.
If it is not hot:
- the heater core may have an air pocket.
- the heater core may be plugged.
- the thermostat may not be working correctly.
Heater Core-Pressure Test
Use the Radiator/Heater Core Pressure Tester to carry out the pressure test.
1. Drain the coolant from the cooling system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and
heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the
radiator/heater core pressure
tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose
clamps.
5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the
pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater
water hoses do not leak, remove the heater
core from the vehicle and carry out the bench test.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7349
Heater Core-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 inch) test heater water hoses with plug and adapter to the core tubes.
Then connect the radiator/heater core pressure tester
to the adapter.
4. Apply 241 kPa (35 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.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Back Flushing-Heater Core
Heater Core: Service and Repair Back Flushing-Heater Core
Special Tools
1. WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these
instructions can result in damage to the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas bottle when removing the pressure
relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly. Step back while the pressure is released from the cooling system. when you are
sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap.
Once pressure is released, remove the pressure relief cap.
2. Partially drain the cooling system.
3. NOTE: Refer to the cooling system Flush-All Operating Instructions for particular vehicle
hook-up.
Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to backflush the heater
core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification
ESR-M14P7A for vehicles filled with Premium Engine Coolant E2FZ-19549-AA or equivalent
meeting Ford specification ESE-M97B44-A (green color). Use warm water for vehicles filled with
Extended Life Engine Coolant F6AZ-19544-AA or equivalent meeting Ford specification
WSS-M97B44-D or DEX-COOL (orange color).
4. Fill the cooling system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Back Flushing-Heater Core > Page 7352
Heater Core: Service and Repair Removal and Installation
REMOVAL
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
1. Remove the plenum chamber. See: Heater Air Plenum Chamber/Service and Repair
2. Remove the screws and the heater core cover.
3. Carefully cut the seal above the heater core inlet and outlet tubes and remove the heater core.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Page 7353
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] >
Component Information > Service and Repair
Heater Air Plenum Chamber: Service and Repair
REMOVAL
1. Remove the rear seat airflow duct. 2. Remove the instrument panel. 3. Drain the coolant from
the radiator so the coolant level is below the heater core.
4. Disconnect the heater water hoses.
5. Inside the vehicle, remove the nut.
6. Disconnect the vacuum hoses.
NOTE: Mark the locations of the vacuum hoses.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] >
Component Information > Service and Repair > Page 7357
7. Disconnect the vacuum hose.
8. Remove the pin-type retainers and remove the vacuum harness.
9. Disconnect the connector.
10. Remove the nuts.
11. Disconnect the connectors.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] >
Component Information > Service and Repair > Page 7358
12. Remove the in-car temperature sensor hose (if equipped).
13. Remove the plenum chamber.
INSTALLATION
1. Position the plenum chamber on the dash panel.
2. Install the nuts.
3. Install the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] >
Component Information > Service and Repair > Page 7359
4. Install the in-car temperature sensor hose (if equipped).
5. Install the connector.
6. Install the vacuum harness.
7. Connect the vacuum hose.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] >
Component Information > Service and Repair > Page 7360
8. Connect the vacuum hoses.
9. Install the heater water hoses.
- Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or
equivalent meeting Ford specification ESF-M99B112-A.
10. Refill the cooling system. 11. Install the heater outlet floor duct. 12. Install the instrument panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
7369
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
7370
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 7376
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 7377
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Page 7378
Heater Hose: Service and Repair
REMOVAL
1. Drain the radiator.
2. Remove the heater hoses from the heater core.
3. Remove the heater hoses from the engine.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or
equivalent meeting Ford specification ESF-M99B112-A.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications > Mechanical Specifications
High Pressure Safety Valve HVAC: Mechanical Specifications
A/C Pressure Relief Valve
..............................................................................................................................................................
5-14 N.m (45-123 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications > Mechanical Specifications > Page 7383
High Pressure Safety Valve HVAC: Pressure, Vacuum and Temperature Specifications
A/C High Pressure Safety Valve
Open ....................................................................................................................................................
..................................... 3103 kPa (450 psi) maximum
Compressor Relief Valve
Open ....................................................................................................................................................
..................................... 3103 kPa (450 psi) maximum
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > A/C High Pressure Safety Valve
High Pressure Safety Valve HVAC: Description and Operation A/C High Pressure Safety Valve
An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube
to:
- relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above).
- prevent damage to the A/C compressor and other system components.
- avoid total refrigerant loss by closing after the excessive pressure has been relieved.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > A/C High Pressure Safety Valve > Page 7386
High Pressure Safety Valve HVAC: Description and Operation Compressor Relief Valve
An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube
to:
- relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above).
- prevent damage to the A/C compressor and other system components.
- avoid total refrigerant loss by closing after the excessive pressure has been relieved.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Service and Repair > A/C High Pressure Safety Valve
High Pressure Safety Valve HVAC: Service and Repair A/C High Pressure Safety Valve
REMOVAL
1. Recover the refrigerant.
2. Remove the A/C compressor pressure relief valve.
INSTALLATION
1. To install, reverse removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Service and Repair > A/C High Pressure Safety Valve > Page 7389
High Pressure Safety Valve HVAC: Service and Repair Compressor Relief Valve
REMOVAL
1. Recover the refrigerant.
2. Remove the A/C compressor pressure relief valve.
INSTALLATION
1. To install, reverse removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation
Hose/Line HVAC: Description and Operation
REFRIGERANT LINES
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C
evaporator core orifice.
The A/C compressor to condenser discharge line contains high pressure refrigerant gas. It has the
following features: an integral non-serviceable muffler
- a fitting used to mount the A/C pressure cut-off switch. (A long-travel Schrader-type valve stem
core is installed in the fitting so that the A/C pressure cut-off switch can be removed without
discharging the A/C system.)
- a fitting used to mount a serviceable high-pressure A/C charge port valve
The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the
following features: The upstream side contains low pressure refrigerant gas.
- The downstream side contains high pressure refrigerant gas and a port to mount the A/C
compressor pressure relief valve.
The accumulator to compressor tube has a fitting used to mount the A/C cycling switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch
can be removed without discharging the A/C system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> A/C Discharge Hose/Line
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line
REMOVAL
1. Disconnect the battery ground cable. 2. Recover the refrigerant.
3. Disconnect the A/C pressure cut-off switch wire harness connector.
4. Remove the A/C pressure cut-off switch.
5. Remove the A/C compressor to condenser discharge line nut.
6. Disconnect the A/C compressor to condenser discharge line from the A/C manifold and tube.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> A/C Discharge Hose/Line > Page 7395
7. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core and
remove the A/C compressor to condenser discharge
line.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> A/C Discharge Hose/Line > Page 7396
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line
Condenser To Evaporator Line
REMOVAL
1. Recover the refrigerant.
2. Disconnect the condenser to evaporator tube from the A/C evaporator core.
3. Disconnect the condenser to evaporator tube from the A/C condenser core and remove the
condenser to evaporator tube.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Evaporator to Compressor Suction Line
REMOVAL
1. Disconnect the battery ground cable. 2. Recover the refrigerant.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> A/C Discharge Hose/Line > Page 7397
3. Disconnect the A/C cycling switch wire harness connector.
4. Remove the A/C cycling switch.
5. Disconnect the evaporator to compressor suction line from the suction accumulator/drier.
6. Disconnect and remove the evaporator to compressor suction line from the A/C manifold and
tube assembly.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Page 7398
Spring Lock Coupling Disconnect Tool Set
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Operation
Receiver Dryer: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The suction accumulator/drier is mounted to the right of the vehicle centerline. The inlet tube of the
suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet
tube of the suction accumulator/drier attaches to the evaporator to compressor suction line.
After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an
internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the
canister.
- A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated
heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate.
- As the heavier mixture passes through the small diameter liquid bleed hole, it has a second
chance to vaporize and recirculate through the A/C compressor without causing compressor
damage due to slugging.
- A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out
refrigerant system contaminant particles.
- A desiccant bag is mounted inside the canister to absorb any moisture which may be in the
refrigerant system.
- A fitting located on the side of the suction accumulator/drier is used to mount a serviceable
low-pressure A/C charge port valve.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants
Technical Service Bulletin # 99-19-6 Date: 990920
A/C - Identification of Non Approved Refrigerants
Article No. 99-19-6
09/20/99
^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS
^ AIR CONDITIONING - PURGING AIR FROM SYSTEM
FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD
1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA
1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO
II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD,
RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000
WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991
CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO
SERIES 1997-1998 AEROMAX, LOUISVILLE
LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000 LS 1998-2000 NAVIGATOR
MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR
1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI
1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER
1997-2000 MOUNTAINEER
MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7406
This TSB article is being republished in its entirety to add model year vehicles
ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are
being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved
refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety,
durability, and performance concerns if they are installed in Ford A/C systems. Identification of the
type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent
dealer service equipment and refrigerant supplies from being contaminated with non-approved
refrigerants.
ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a
recovery machine to prevent cross-contamination of the recovery machine and other A/C systems
being serviced with that recovery machine. Refer to the following text.
OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4
SUPERSEDES: 98-12-8
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
991906A Test A/C System For 0.3 Hr.
Contaminated Refrigerant
DEALER CODING
CONDITION
BASIC PART NO. CODE
R-12 49
OASIS CODES: 208000, 208999
A/C Refrigerant Analyzer Function
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7407
Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for
use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a
quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or
flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system
and automatically purge air from the system.
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from
automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes
through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor
calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid
Crystal Display (LCD).
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the
sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green
"PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity
levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will
light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and
"HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards.
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or
above. The analyzer eliminates the effect of air
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7408
when determining the refrigerant sample content because air is not considered a contaminant
although air can affect A/C system performance. Air will automatically be purged until a pure
refrigerant with a less than 2% by weight air measurement is reached.
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12
recovery/recycling equipment. Take the following actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any additional cost to repair the
system. The customer may wish to return to the service facility which performed the last A/C
service.
3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover
contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C
service facility in your area which has the proper equipment for refrigerant recovery.
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the
system. Ford recommends that you do the following to be sure a quality repair is made:
1. Determine the cause of the failure.
2. Determine which parts will need to be replaced.
3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated
refrigerant.
4. Install a new suction/accumulator.
5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present
in the system.
6. Evacuate the system for 45 minutes.
7. Recharge the system, verify proper operation, and leak test.
Disposal of Contaminated Refrigerant
Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are
companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not
evaluated the processes of the listed refrigerant disposal companies and is not endorsing or
promoting their companies Business transactions are between the dealership and disposal
companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip
cylinder shipping.
^ Omega Refrigerant Reclamation
^ 5263 North Fourth St.
^ Irwindale, CA 91706
^ (310) 698-0991 FAX: (310) 696-7908
^ Full Cycle Global
^ 2966 Wireton
^ Blue Island, IL 60406
^ (708) 388-8551 FAX: (708) 399-6550
^ U.S. Refrigerant Reclaim, Inc.
^ 12420 North Green River Road
^ Evansville, IN 47711
^ (800) 207-5931 FAX: (812) 867-1463
^ Full Cycle Global
^ 343 South Airline Highway
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7409
^ Gonzales, LA 70737
^ (504) 644-5333 FAX: (504) 644-1609
^ CFC Reclamation
^ 1321 Swift North
^ Kansas City, MO 64116
^ (816) 471-2511
^ Full Cycle Global
^ 550 James St.
^ Lakewood, NJ 08701
^ (908) 370-3400 FAX: (908) 370-3088
^ National Refrigerants, Inc.
^ 11401 Roosevelt Blvd.
^ Philadelphia, PA 19154
^ (215) 698-6620 FAX: (215) 602-8205
^ Gartech Refrigerant Reclamation
^ 2002 Platinum
^ Garland, TX 75042
^ (214) 272-4070 FAX: (214) 272-6548
^ Refrigerant Reclaim Services
^ 121 S. Norwood Dr.
^ Hurst, TX 76053-7807
^ (817) 282-0022 FAX: (800) 831-6182
^ Full Cycle Global
^ 2055 Silber, Suite 109
^ Houston, TX 77055
^ (713) 681-7370 FAX: (713) 681-9947
^ Refrigerant Reclaim, Inc.
^ 122 Old Stage Coach Road
^ Dumfries, VA 22026
^ (800) 238-5902 FAX: (703) 441-0393
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant Capacity ............................................................................................................................
........................................................... 1.08 kg (38 oz)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 7412
Refrigerant: Fluid Type Specifications
Refrigerant............................................................................................................................................
........................................................................R134a
Ford Part Number ................................................................................................................................
..................................................................... YN-19
Ford Specification ................................................................................................................................
................................................... WSH-M17B19-A
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Oil Capacity .........................................................................................................................................
........................................................... 222 ml (7.5 oz)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7417
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil......................................................................................................................................
...Polyalkylene Glycol (PAG) Oil (R-134a Systems)
Ford Part Number
...........................................................................................................................................................
F7AZ-19589-AD (MC-YN-12C)
Ford Specification ................................................................................................................................
.................................................. WSH-M1C231-B
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Mechanical Specifications
Refrigerant Pressure Sensor / Switch: Mechanical Specifications
A/C Pressure Cut-off Switch
.....................................................................................................................................................
6.8-13.6 N.m (61-120 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Mechanical Specifications > Page 7422
Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications
A/C Cycling Switch
Close ...................................................................................................................................................
.................................... 276-324 kPa (40-47 psi) Open .......................................................................
................................................................................................................ 152-193 kPa (22-28 psi)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Pressure Cutoff Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch
The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the A/C
compressor to condenser discharge line.
- A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch
contacts open, disengaging the A/C compressor.
- When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow
operation of the A/C compressor.
- It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Pressure Cutoff Switch > Page 7425
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction
accumulator/driver.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction or low side pressure to control the operation of the A/C cycling switch.
- The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi).
- The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi).
- When the A/C cycling switch contacts close, the A/C clutch field coil is energized.
- When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of airflow.
- It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Service and Repair > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch
REMOVAL
1. Disconnect the wire harness connector.
2. Remove the A/C cycling switch.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Service and Repair > A/C Cycling Switch > Page 7428
Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch
REMOVAL
1. Disconnect the wire harness connector.
2. Remove the A/C pressure cut-off switch.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7433
Compressor Clutch Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7434
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 7439
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 7440
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Blower Motor Speed Control
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Blower Motor Speed Control > Page 7443
Control Module HVAC: Diagrams Electronic Climate Control Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Description and Operation > Blower Motor Speed Control
Control Module HVAC: Description and Operation Blower Motor Speed Control
The A/C blower motor speed control is located on the A/C evaporator housing, in the engine
compartment.
- The function of the A/C blower motor speed control is to convert low power signals from the
electronic automatic temperature control module to a high current, variable ground feed for the
blower motor.
- Blower motor speed is infinitely variable and is controlled by the electronic automatic temperature
control module software.
- A delay function provides a gradual increase or decrease in blower motor speed under all
conditions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Description and Operation > Blower Motor Speed Control > Page 7446
Control Module HVAC: Description and Operation Electronic Climate Control Module
The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel,
has the following features:
- a blower speed override control for manual input
- a vacuum fluorescent display for displaying set temperature, ambient temperature, function and
Diagnostic Trouble Codes (DTCs)
- an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes
(DTCs). These DTCs direct the technician to the inoperative component.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Service and Repair > Blower Motor Speed Control
Control Module HVAC: Service and Repair Blower Motor Speed Control
REMOVAL
1. Disconnect the wire harness connector. 2. Drain the cooling system below the heater hoses.
3. Disconnect the heater hose.
4. Remove the screws and remove the blower motor speed control.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Service and Repair > Blower Motor Speed Control > Page 7449
Control Module HVAC: Service and Repair Electronic Climate Control Module
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the screws and pull the Electronic Automatic Temperature Control (EATC) module from
the instrument panel.
4. Remove the EATC module.
- Remove the nuts and the vacuum harness.
- Disconnect the wire harness connectors and remove the EATC module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Service and Repair > Blower Motor Speed Control > Page 7450
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Air Temperature
Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation
Ambient Air Temperature Sensor: Description and Operation
The A/C ambient air temperature sensor and bracket:
- is located in front of the A/C condenser core near the center of the vehicle.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the electronic automatic temperature control assembly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Air Temperature
Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Description and Operation > Page
7455
Ambient Air Temperature Sensor: Service and Repair
REMOVAL
1. Remove the radiator upper sight shield.
2. Disconnect the wire harness connector.
3. Remove the A/C ambient air temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > In-Car Temperature Sensor <-->
[Cabin Temperature Sensor / Switch] > Component Information > Description and Operation
In-Car Temperature Sensor: Description and Operation
The in-car temperature sensor operates in the following manner:
- A thermistor in the in-car temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the A/C
evaporator housing and the in-car temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the A/C evaporator
housing air stream to create a suction in the in-car temperature sensor.
- The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > In-Car Temperature Sensor <-->
[Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 7459
In-Car Temperature Sensor: Service and Repair
REMOVAL
1. Remove the finish panel.
2. Disconnect the connector.
3. Remove the screws and pull the control assembly away from the instrument panel.
4. Remove the screws and position the in-car temperature sensor to access the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > In-Car Temperature Sensor <-->
[Cabin Temperature Sensor / Switch] > Component Information > Description and Operation > Page 7460
5. Disconnect the connector.
6. Disconnect the hose and remove the in-car temperature sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Mechanical Specifications
Refrigerant Pressure Sensor / Switch: Mechanical Specifications
A/C Pressure Cut-off Switch
.....................................................................................................................................................
6.8-13.6 N.m (61-120 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 7465
Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications
A/C Cycling Switch
Close ...................................................................................................................................................
.................................... 276-324 kPa (40-47 psi) Open .......................................................................
................................................................................................................ 152-193 kPa (22-28 psi)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch
The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the A/C
compressor to condenser discharge line.
- A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch
contacts open, disengaging the A/C compressor.
- When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow
operation of the A/C compressor.
- It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 7468
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction
accumulator/driver.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction or low side pressure to control the operation of the A/C cycling switch.
- The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi).
- The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi).
- When the A/C cycling switch contacts close, the A/C clutch field coil is energized.
- When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of airflow.
- It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch
REMOVAL
1. Disconnect the wire harness connector.
2. Remove the A/C cycling switch.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 7471
Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch
REMOVAL
1. Disconnect the wire harness connector.
2. Remove the A/C pressure cut-off switch.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Description and Operation
Solar Sensor: Description and Operation
The A/C sunload sensor:
- is located on the top RH side of the instrument panel above the glove compartment.
- contains a photovoltaic diode that is sensitive to light.
- has some unspecified resistance across the terminals depending upon the amount of light
reaching the photovoltaic diode; therefore the only test that can be performed is for an internal
short circuit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Description and Operation > Page 7475
Solar Sensor: Service and Repair
REMOVAL
1. Remove the instrument panel upper finish panel.
2. Disconnect the wire harness connector.
3. Remove the A/C sunload sensor from the instrument panel upper finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and
Operation
Service Port HVAC: Description and Operation
Service Gauge Port Values
The high-pressure service gauge port valve is located on the front A/C manifold and tube.
The low pressure service gauge port valve is located on the suction accumulator/drier.
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 new Schrader-type valve core can be installed if the seal leaks.
- Always install the A/C charging valve cap on the service gauge port valves afier repairing the
refrigerant system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and
Operation
Solar Sensor: Description and Operation
The A/C sunload sensor:
- is located on the top RH side of the instrument panel above the glove compartment.
- contains a photovoltaic diode that is sensitive to light.
- has some unspecified resistance across the terminals depending upon the amount of light
reaching the photovoltaic diode; therefore the only test that can be performed is for an internal
short circuit.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and
Operation > Page 7482
Solar Sensor: Service and Repair
REMOVAL
1. Remove the instrument panel upper finish panel.
2. Disconnect the wire harness connector.
3. Remove the A/C sunload sensor from the instrument panel upper finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and
Repair
Vacuum Harness HVAC: Service and Repair
Vacuum Pump Kit
Special Tool(S)
1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of
standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the
damaged area of the mini-tube
vacuum hose.
3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose
ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent
will seal the mini-tube
in the vacuum hose.
WARNING: Read the warning information on the product label to prevent possible personal injury.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the
standard 1/8 inch repair vacuum hose section. 6. Shake the repair joint after assembly to make
sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum
leak in the repair area.
- Use the Vacuum Tester or equivalent.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and
Repair > Page 7486
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service
and Repair
Vacuum Reservoir HVAC: Service and Repair
REMOVAL
1. Remove the relay module.
2. Disconnect the vacuum hose. 3. Raise the vehicle.
4. From inside the LH wheel well, remove the nuts. 5. Remove the vacuum reservoir tank.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Arming and Disarming > Page 7497
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications
Air Bag: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Driver air bag module bolts ..................................................................................................................
........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts .......................
.............................................................................................................................................. 9 Nm (80
Lb-In) Air bag sensor bolts ..................................................................................................................
.................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts .......................
...................................................................................................................................................... 15
Nm (11 Lb-Ft) Forwarded Steering column nuts .................................................................................
.............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw
weld nut repair screw (8 mm)
....................................................................................................................... 12 Nm (9 Lb-Ft)
Grounding screw (6 mm) .....................................................................................................................
......................................................... 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver
Air Bag Module
Air Bag: Locations Driver Air Bag Module
The driver air bag module:
- is replaced as an assembly.
- is mounted in the center of the steering wheel.
Air Bag Sliding Contact The air bag sliding contact: is mounted on the steering column, behind the steering wheel.
- continuously transfers electrical signals from the driver air bag module to the air bag Electronic
Crash Sensor (ECS) module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver
Air Bag Module > Page 7503
Air Bag: Locations Passenger Airbag
The passenger air bag module:
- is replaced as an assembly.
- is mounted in the RH side of the instrument panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page
7504
Air Bag: Service Precautions
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be replaced, not repainted.
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches. The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and
Operation > Driver Air Bag Module
Air Bag: Description and Operation Driver Air Bag Module
The driver air bag module:
- is replaced as an assembly.
- is mounted in the center of the steering wheel.
Air Bag Sliding Contact The air bag sliding contact: is mounted on the steering column, behind the steering wheel.
- continuously transfers electrical signals from the driver air bag module to the air bag Electronic
Crash Sensor (ECS) module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and
Operation > Driver Air Bag Module > Page 7507
Air Bag: Description and Operation Passenger Air Bag Module
The passenger air bag module:
- is replaced as an assembly.
- is mounted in the RH side of the instrument panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module
Air Bag: Service and Repair Driver Air Bag Module
REMOVAL
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be replaced, not repainted.
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the two driver air bag module retaining bolts.
3. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch
electrical connector. 3. Remove the driver air bag module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7510
1. Follow the removal procedure in reverse order.
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7511
Air Bag: Service and Repair General Procedures
Air Bag Disposal-Deployed Air Bag
1. Dispose of the deployed air bag modules in the same manner as any other part to be scrapped.
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
Air Bag Disposal-Undeployed Air Bag, Inoperative
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
1 Remove the inoperative driver air bag module or passenger air bag module.
NOTE: All inoperative air bag modules have been placed on the Mandatory Return List. All
discolored or damaged air bag modules should treated the same as any inoperative live air bag
being returned.
2 When installing a new driver air bag module, record the necessary information and return the
inoperative driver air bag module to Ford Motor Company.
NOTE: When installing a new air bag module, a prepaid return postcard is provided with the
replacement air bag module. The serial number for the new part and the Vehicle Identification
Number (VIN) must be recorded and sent to Ford Motor Company.
3. When installing a new passenger air bag module, record the necessary information and return
the inoperative passenger air bag module to Ford
Motor Company.
Air Bag Disposal-Undeployed Air Bag, Scrapped Vehicle
Remote Deployment
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet)
away to ensure personal safety. Due to the loud report which occurs when the air bag is deployed,
hearing protection is required.
- Do not place the driver or passenger air bag module with the trim cover or deployment door facing
down, as the forces of the deploying air bag can cause it to ricochet and cause personal injury.
NOTE: The passenger air bag module is shown. The driver air bag module is similar.
1. Remove the passenger air bag module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7512
2. Cut the two connector wires on the passenger air bag module, and strip 25 mm (1 in) of
insulation from the ends of the wires.
3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and connect one end of
each wire to each of the wires on the passenger air
bag module.
4. Place the passenger air bag module on a flat surface with the deployment door facing upward in
an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the passenger air bag
module.
6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt
battery. 7. Allow at least ten minutes before approaching the deployed air bag to allow for cooling.
8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped.
Wiring Repair
1. Inspect the Supplemental Restraint System (SRS) wiring and the wiring harness for any damage
that may have occurred as a result of the accident.
Inspect and repair or install new, as required, any damaged: insulation.
- terminal.
- connectors.
- splices.
2. Splice damaged wires using the specified butt-splice connector or equivalent.
- For splices required in adjacent wiring, stagger the splices 51 mm (2.04 in) apart from each other.
- Use waterproof butt-splice type connectors.
- Use the correct size heat shrink nylon tube to prevent water, salt, condensation, and heat from
affecting the wiring repair. Make sure the tube extends 25 mm (1 in) each side of the repair.
- Use a splice connector that is lined with a sealer that melts when heated with a heat gun and
flows from the tubing, sealing the splice.
- Use the correct gauge connector for the wire being repaired.
- Use connectors that are transparent to allow inspection of the finished splice.
Connector identification
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7513
Description ...........................................................................................................................................
............................................................ Specification
Butt connector gauge 18-22
......................................................................................................................................................
Red, Class C E6FZ-14488-A Butt connector gauge 14-16
.....................................................................................................................................................
Blue, Class C E6FZ-14488-B Butt connector gauge 10-12
................................................................................................................................................. Yellow,
Class C E6FZ-14488-C
"J" Nut, Electronic Crash Sensor (ECS) and Front Crash Sensor
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE:
- There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
- If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld
nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Electronic Crash Sensor
(ECS) and Front Crash Sensor.
- The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part numbers N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N80085-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J" nut through the
rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification.
Missing Weld Nut, Electronic Crash Sensor & Front Crash Sensor
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE:
- There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
- If two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair "J" Nut, Electronic Crash Sensor (ECS) and Front Crash Sensor. Weld nuts must be installed as
outlined in this procedure.
- Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7514
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification.
Stripped Weld Nut, Electronic Crash Sensor & Front Crash Sensor
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out
weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the
vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the
remaining attaching screws. 6. Tighten the attaching screws to specification.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7515
Air Bag: Service and Repair Passenger Air Bag Module
REMOVAL
WARNING:
- If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS)
module.
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment
which can result in personal injury.
- Air bag modules with discolored or damaged deployment doors must be installed new, not
repainted.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove
compartment and disconnect the glove compartment isolator.
3. Push in on the two glove compartment door tabs and position downward.
4. Separate the trim panel by pulling straight out to release the retaining clips.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7516
5. Remove the trim panel.
1 Disconnect the clock.
2 Remove the trim panel.
6. Disconnect the passenger air bag module.
1 Disconnect the passenger air bag module electrical connector.
2 Remove the passenger air bag module retaining bolts.
7. Remove the passenger side air bag module.
1 Remove the two retaining screws.
2 Placing one hand in the glove box opening, push the passenger air bag out from the instrument
panel and remove it.
INSTALLATION
WARNING:
- If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS)
module.
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment
which can result in personal injury.
NOTE:
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
- Make sure to tighten the retaining bolts to specification.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7517
1. Follow the removal procedure in reverse order.
- Make sure the retaining clips on the back of the air bag module are fully seated in the slots in the
substrate.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7518
Air Bag: Service and Repair Removal and Installation
Driver's Side
REMOVAL
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be replaced, not repainted.
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the two driver air bag module retaining bolts.
3. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch
electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7519
3. Remove the driver air bag module.
INSTALLATION
1. Follow the removal procedure in reverse order.
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Passenger's Side
REMOVAL
WARNING:
- If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS)
module.
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment
which can result in personal injury.
- Air bag modules with discolored or damaged deployment doors must be installed new, not
repainted.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove
compartment and disconnect the glove compartment isolator.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7520
3. Push in on the two glove compartment door tabs and position downward.
4. Separate the trim panel by pulling straight out to release the retaining clips.
5. Remove the trim panel.
1 Disconnect the clock.
2 Remove the trim panel.
6. Disconnect the passenger air bag module.
1 Disconnect the passenger air bag module electrical connector.
2 Remove the passenger air bag module retaining bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7521
7. Remove the passenger side air bag module.
1 Remove the two retaining screws.
2 Placing one hand in the glove box opening, push the passenger air bag out from the instrument
panel and remove it.
INSTALLATION
WARNING:
- If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS)
module.
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment
which can result in personal injury.
NOTE:
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
- Make sure to tighten the retaining bolts to specification.
1. Follow the removal procedure in reverse order.
- Make sure the retaining clips on the back of the air bag module are fully seated in the slots in the
substrate.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications
Air Bag Control Module: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Driver air bag module bolts ..................................................................................................................
........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts .......................
.............................................................................................................................................. 9 Nm (80
Lb-In) Air bag sensor bolts ..................................................................................................................
.................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts .......................
...................................................................................................................................................... 15
Nm (11 Lb-Ft) Forwarded Steering column nuts .................................................................................
.............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw
weld nut repair screw (8 mm)
....................................................................................................................... 12 Nm (9 Lb-Ft)
Grounding screw (6 mm) .....................................................................................................................
......................................................... 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 7525
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 7526
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 7527
Air Bag Control Module: Service Precautions
WARNING:
- The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 7528
Air Bag Control Module: Description and Operation
The air bag Electronic Crash Sensor (ECS) module performs the following functions:
- signals the inflators to deploy the air bags in the event of a deployable crash.
- monitors the air bag Supplemental Restraint System (SRS) for faults.
- illuminates the air bag indicator if a fault is detected.
- flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
- communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble
Codes (DTCs).
- signals the Lighting Control Module (LCM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the ECS and is not serviced separately.
The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the
RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will flash the two-digit
LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of
the key cycle. The ECS will also communicate the current and historical DTCs the DLC, using the
New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system
detects a fault condition, the ECS will signal the LCM to activate an audible chime. The chime is a
series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator
require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed first. After the fault has been corrected, the next highest priority fault will be
displayed.
The ECS includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors close. The backup power supply will deplete its stored energy approximately 1 minute
after the battery ground cable is disconnected.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 7529
Air Bag Control Module: Service and Repair
REMOVAL
WARNING:
- The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the RH sill plate. 3. Position the carpet out of the way.
4. Remove the ECS.
1 Disconnect the ECS electrical connector locking clip.
2 Disconnect the ECS electrical connector.
3 Remove the three retaining screws.
4 Remove the ECS module and bracket.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 7530
1. Follow the removal procedure in reverse order.
WARNING: The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- The tightening torque of the air bag electronic crash sensor (ECS) module bracket retaining
screws is critical for correct system operation.
NOTE: Make sure to tighten the retaining bolts to specification.
- A repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions
Clockspring Assembly / Spiral Cable: Service Precautions
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE.
- CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
- DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
- NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN
AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
- AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
REPLACED, NOT REPAINTED.
- VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT
THE AIR BAG IS DEPLOYED.
- TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP
POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE
MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO
EQUIPPED).
NOTE: Repair of the air-bag sliding contact (clock-spring) is made by REPLACEMENT only. If a
part is replaced and the new part does not correct the condition, install the original part. Perform
the diagnostic procedure again.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7534
Clockspring Assembly / Spiral Cable: Service and Repair
REMOVAL
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be installed new, not repainted.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag
module. 3. Remove the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation
when the air bag sliding contact is removed.
5. Place the steering Column in the full down tilt position, then remove the tilt wheel handle and
shank.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7535
6. Remove the lower steering column cover.
1 Remove the two bolts.
2 Position the parking brake release aside.
3 Remove the lower steering column cover.
7. Remove the lower steering column reinforcement.
1 Remove the five bolts.
2 Remove the lower steering column reinforcement.
8. Remove the lower steering column shroud.
1 Remove the four screws.
2 Remove the lower steering column shroud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7536
9. Remove the ignition switch lock cylinder.
1 Position the ignition switch lock cylinder to the RUN position.
2 Using a suitable tool, push upward on the cylinder release tab while pulling the ignition switch
lock cylinder outward.
10. Remove the instrument panel lower insulator.
11. Loosen the forward steering column mounting nuts.
12. Disconnect the transmission range indicator cable.
13. Loosen the aft steering column mounting nuts and allow the steering column to drop down
enough for clearance to remove the upper steering
column shroud.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7537
14. Remove the upper steering column shroud.
15. Remove the Passive Anti-theft System (PATS) transmitter.
1 Remove the PATS transmitter retaining screw.
2 Remove the PATS transmitter.
16. Remove the key-in-ignition warning indicator switch.
17. Disconnect the air bag sliding contact electrical connectors.
1 Cut and remove the tie strap.
2 Separate the wires from the wiring harness retainer.
3 Remove the sliding contact electrical connectors from the wire connector bracket, then
disconnect the connectors.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7538
18. Remove the air bag sliding contact.
1. Pry the air bag sliding contact retaining clips loose. 2. Remove the air bag sliding contact.
INSTALLATION
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Position and install the air bag sliding contact.
1 Install the air bag sliding contact on the steering column.
2 Make sure the retaining clips are engaged.
2. Connect the air bag sliding contact electrical connectors.
1 Connect the air bag sliding contact electrical connectors and install into the wire connector
bracket.
2 Install the wires into the wiring harness retainer.
3 Install a new tie strap.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7539
3. Install the key-in-ignition warning indicator switch.
4. Install the passive anti-theft system (PATS) transmitter.
1 Position the PATS transmitter.
2 Install the PATS transmitter retaining screw.
5. Install the upper steering column shroud.
6. Install the ignition switch lock cylinder.
- Position the ignition switch lock cylinder to the RUN position.
- Insert the ignition switch lock cylinder into the steering column.
- Make sure the ignition switch lock cylinder is fully seated and aligned in the inter-locking washer
before turning the key to the OFF position.
- Make sure the ignition switch lock cylinder retaining pin is seated in the hole in the steering
column.
- Rotate the ignition switch lock cylinder through all positions to verify operation.
7. Position the steering column up and hand-tighten the forward steering column mounting nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7540
8. Connect the transmission range indicator cable.
9. Tighten the aft steering column mounting nuts.
10. Tighten the forward steering column mounting nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7541
11. Install the lower steering column shroud.
1 Position the lower steering column shroud.
2 Install the four retaining screws.
12. Install the lower steering column reinforcement.
1 Position the lower steering column reinforcement.
2 Install the five bolts.
13. Install the lower steering column cover.
1 Position the lower steering column cover.
2 Position the parking brake release.
3 Install the two bolts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 7542
14. Install the tilt wheel handle and shank.
15. Remove the two strips of masking tape across the air bag sliding contact. 16. Install the
steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
17. Install the driver air bag module. 18. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Specifications
Impact Sensor: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Specifications > Page 7546
Impact Sensor: Service Precautions
WARNING:
- Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag
Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Specifications > Page 7547
Impact Sensor: Service and Repair
REMOVAL
WARNING:
- Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag
Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator upper
sight shield.
3. Remove the air bag sensor.
1 Disconnect the air bag sensor electrical connector.
2 Remove the three screws.
3 Remove the air bag sensor.
INSTALLATION
1. Follow the removal procedure in reverse order.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Specifications > Page 7548
auxiliary batteries and power supplies (if equipped).
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side Air Bag Module
Side Air Bag: Service and Repair Driver Side Air Bag Module
REMOVAL
WARNING:
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged trim covers must be replaced, not repainted.
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the two driver air bag module retaining bolts.
3. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch
electrical connector. 3. Remove the driver air bag module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side Air Bag Module > Page 7553
1. Follow the removal procedure in reverse order.
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side Air Bag Module > Page 7554
Side Air Bag: Service and Repair Passenger Side Air Bag
REMOVAL
WARNING:
- If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS)
module.
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment
which can result in personal injury.
- Air bag modules with discolored or damaged deployment doors must be installed new, not
repainted.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove
compartment and disconnect the glove compartment isolator.
3. Push in on the two glove compartment door tabs and position downward.
4. Separate the trim panel by pulling straight out to release the retaining clips.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side Air Bag Module > Page 7555
5. Remove the trim panel.
1 Disconnect the clock.
2 Remove the trim panel.
6. Disconnect the passenger air bag module.
1 Disconnect the passenger air bag module electrical connector.
2 Remove the passenger air bag module retaining bolts.
7. Remove the passenger side air bag module.
1 Remove the two retaining screws.
2 Placing one hand in the glove box opening, push the passenger air bag out from the instrument
panel and remove it.
INSTALLATION
WARNING:
- If installing a new air bag module, always install a new air bag Electronic Crash Sensor (ECS)
module.
- Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment
which can result in personal injury.
NOTE:
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
- Make sure to tighten the retaining bolts to specification.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Driver Side Air Bag Module > Page 7556
1. Follow the removal procedure in reverse order.
- Make sure the retaining clips on the back of the air bag module are fully seated in the slots in the
substrate.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Description and Operation
Malfunction Lamp / Indicator: Description and Operation
The air bag warning indicator is controlled by the air bag Electronic Crash Sensor (ECS). When
starting the vehicle, the air bag warning indicator illuminates and remains lit for six seconds. The
indicator only illuminates after starting the vehicle if a Supplemental Restraint System (SRS)
malfunction is detected.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Description and Operation > Page 7560
Malfunction Lamp / Indicator: Testing and Inspection
For testing procedures for this component, refer to Restraint Systems, Air Bag Systems, Testing
and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications
Air Bag Control Module: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Driver air bag module bolts ..................................................................................................................
........................................................ 12 Nm (9 Lb-Ft) Passenger air bag module bolts .......................
.............................................................................................................................................. 9 Nm (80
Lb-In) Air bag sensor bolts ..................................................................................................................
.................................................................... 12 Nm (9 Lb-Ft) Aft steering column nuts .......................
...................................................................................................................................................... 15
Nm (11 Lb-Ft) Forwarded Steering column nuts .................................................................................
.............................................................................. 15 Nm (11 Lb-Ft) Crash sensor grounding screw
weld nut repair screw (8 mm)
....................................................................................................................... 12 Nm (9 Lb-Ft)
Grounding screw (6 mm) .....................................................................................................................
......................................................... 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 7565
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 7566
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 7567
Air Bag Control Module: Service Precautions
WARNING:
- The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 7568
Air Bag Control Module: Description and Operation
The air bag Electronic Crash Sensor (ECS) module performs the following functions:
- signals the inflators to deploy the air bags in the event of a deployable crash.
- monitors the air bag Supplemental Restraint System (SRS) for faults.
- illuminates the air bag indicator if a fault is detected.
- flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
- communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble
Codes (DTCs).
- signals the Lighting Control Module (LCM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the ECS and is not serviced separately.
The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the
RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will flash the two-digit
LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of
the key cycle. The ECS will also communicate the current and historical DTCs the DLC, using the
New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system
detects a fault condition, the ECS will signal the LCM to activate an audible chime. The chime is a
series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator
require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed first. After the fault has been corrected, the next highest priority fault will be
displayed.
The ECS includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors close. The backup power supply will deplete its stored energy approximately 1 minute
after the battery ground cable is disconnected.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 7569
Air Bag Control Module: Service and Repair
REMOVAL
WARNING:
- The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the RH sill plate. 3. Position the carpet out of the way.
4. Remove the ECS.
1 Disconnect the ECS electrical connector locking clip.
2 Disconnect the ECS electrical connector.
3 Remove the three retaining screws.
4 Remove the ECS module and bracket.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 7570
1. Follow the removal procedure in reverse order.
WARNING: The air bag Electronic Crash Sensor (ECS) orientation is critical for correct system operation. If a
vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a
collision in which the right cowl A-pillar area has been damaged, inspect the mounting and bracket
for deformation. If damaged, the (ECS) must be replaced whether or not the air bags have
deployed. In addition, make sure the area of the (ECS) mounting is restored to its original
condition.
- If installing a new air bag module, always install a new air bag electronic crash sensor (ECS)
module.
- The tightening torque of the air bag electronic crash sensor (ECS) module bracket retaining
screws is critical for correct system operation.
NOTE: Make sure to tighten the retaining bolts to specification.
- A repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Arming and Disarming > Page 7577
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Description and Operation
Child Seat Tether Attachment: Description and Operation
If a child safety belt anchor tether is required for the child safety seat, a child safety belt anchor
tether kit can be obtained free from any Ford or Lincoln-Mercury dealer. Attachment holes at each
rear seating position have been provided in all vehicles.
WARNING: It is important that the bolt/anchor be securely tightened to specification. Otherwise, the
child safety seat may not be correctly secured and the child could be injured in case of a sudden
stop or accident.
Instructions for installing the child safety belt anchor tether kit are included in the kit with the tether
attachment.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement
Technical Service Bulletin # 00S15 Date: 000901
Recall - Seat Belt Retractor Inspection/Replacement
SAFETY RECALL 00S15
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and,
if Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7590
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7591
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7592
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions of Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7593
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7594
Table 1 * # 150 * Crown Victoria/Grand Marquis
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7595
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7596
Table 2 **150* Town Car
DEALER PRICE For latest prices, refer to:
^ DOES II
^ Updated Price Book
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7597
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
LEFT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front left-hand seat belt retractor. The build label is located at one of two possible places on the
seat belt webbing. Some minor disassembly may be required to access the build label. An affected
seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected
by the build date will be replaced. Follow the appropriate procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7598
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7599
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7600
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7601
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7602
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7603
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page
7604
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement
Technical Service Bulletin # 00S16 Date: 000901
Recall - Seat Belt Inspection/Replacement
00S16 SAFETY RECALL
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection
and, If Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7609
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7610
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7611
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions on Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7612
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7613
Table 1 * # 150 * Crown Victoria/Grand Marquis
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7614
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7615
Table 2 * # 150 * Town Car
DEALER PRICE For latest prices refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
RIGHT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front right-hand seat belt retractor. The build label is located at one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7616
of two possible places on the seat belt webbing. Some minor disassembly may be required to
access the build label. An affected seat belt retractor will be identified by the build date. Only a seat
belt retractor determined affected by the build date will be replaced. Follow the appropriate
procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7617
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7618
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7619
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7620
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7621
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7622
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7623
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > NHTSA00V157001 > Jun > 00 > Recall 00V157001: Service Stock Seat Belt
Assemblies
Seat Belt: Recalls Recall 00V157001: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket driver's seat belt assemblies that were
sold by Ford Parts Departments from January 1, through June 13, 2000. These seat belt
assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt Assemblies." The
equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977, H 9979, T 9063,
and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from June 1, 1998
through May 21, 2000. Some of these seat belt assemblies may have been installed as service
replacement equipment on the vehicles involved in there call. In the event of a collision, these seat
belts may not restrain an occupant increasing the risk of injury. Dealers will inspect these vehicles
and replace the Service Seat Belt Assemblies that were installed in these vehicles from January 1
through June 13, 2000. Owner notification is expected to begin during late July 2000. Owners who
take their vehicles to an authorized dealer on an agreed upon service date and do not receive the
free remedy within a reasonable time should contact Ford at1-800-392-3673. Also contact the
National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
1996 FORD CROWN VICTORIA
1996 LINCOLN TOWN CAR
1996 MERCURY GRAND MARQUIS
1997 FORD CROWN VICTORIA
1997 LINCOLN TOWN CAR
1997 MERCURY GRAND MARQUIS
1998 FORD CROWN VICTORIA
1998 LINCOLN TOWN CAR
1998 MERCURY GRAND MARQUIS
1999 FORD CROWN VICTORIA
1999 LINCOLN TOWN CAR
1999 MERCURY GRAND MARQUIS
2000 FORD CROWN VICTORIA
2000 LINCOLN TOWN CAR
2000 MERCURY GRAND MARQUIS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > NHTSA00V157002 > Jun > 00 > Recall 00V157002: Service Stock Seat Belt
Assemblies
Seat Belt: Recalls Recall 00V157002: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket front passenger side seat belt
assemblies that were sold by Ford Parts Departments from January 1, through June 13, 2000.
These seat belt assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt
Assemblies." The equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977,
H 9979, T 9063, and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from
June 1, 1998 through May 21, 2000. Some of these seat belt assemblies may have been installed
as service replacement equipment on the vehicles involved in the recall. In the event of a collision,
these seat belts may not restrain an occupant increasing the risk of injury. Dealers will inspect
these vehicles and replace the Service Seat Belt Assemblies that were installed in these vehicles
from January 1 through June 13, 2000. Owner notification is expected to begin during late July
2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and
do not receive the free remedy within a reasonable time should contact Ford at1-800-392-3673.
Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at
1-888-DASH-2-DOT (1-888-327-4236).
1996 FORD CROWN VICTORIA
1996 LINCOLN TOWN CAR
1996 MERCURY GRAND MARQUIS
1997 FORD CROWN VICTORIA
1997 LINCOLN TOWN CAR
1997 MERCURY GRAND MARQUIS
1998 FORD CROWN VICTORIA
1998 LINCOLN TOWN CAR
1998 MERCURY GRAND MARQUIS
1999 FORD CROWN VICTORIA
1999 LINCOLN TOWN CAR
1999 MERCURY GRAND MARQUIS
2000 FORD CROWN VICTORIA
2000 LINCOLN TOWN CAR
2000 MERCURY GRAND MARQUIS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement
Technical Service Bulletin # 00S15 Date: 000901
Recall - Seat Belt Retractor Inspection/Replacement
SAFETY RECALL 00S15
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and,
if Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7637
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7638
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7639
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions of Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7640
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7641
Table 1 * # 150 * Crown Victoria/Grand Marquis
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7642
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7643
Table 2 **150* Town Car
DEALER PRICE For latest prices, refer to:
^ DOES II
^ Updated Price Book
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7644
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
LEFT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front left-hand seat belt retractor. The build label is located at one of two possible places on the
seat belt webbing. Some minor disassembly may be required to access the build label. An affected
seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected
by the build date will be replaced. Follow the appropriate procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7645
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7646
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7647
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7648
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7649
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7650
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7651
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement
Technical Service Bulletin # 00S16 Date: 000901
Recall - Seat Belt Inspection/Replacement
00S16 SAFETY RECALL
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection
and, If Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7656
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7657
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7658
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions on Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7659
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7660
Table 1 * # 150 * Crown Victoria/Grand Marquis
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7661
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7662
Table 2 * # 150 * Town Car
DEALER PRICE For latest prices refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
RIGHT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front right-hand seat belt retractor. The build label is located at one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7663
of two possible places on the seat belt webbing. Some minor disassembly may be required to
access the build label. An affected seat belt retractor will be identified by the build date. Only a seat
belt retractor determined affected by the build date will be replaced. Follow the appropriate
procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7664
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7665
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7666
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7667
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7668
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7669
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7670
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA00V157001 > Jun > 00 > Recall 00V157001:
Service Stock Seat Belt Assemblies
Seat Belt: All Technical Service Bulletins Recall 00V157001: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket driver's seat belt assemblies that were
sold by Ford Parts Departments from January 1, through June 13, 2000. These seat belt
assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt Assemblies." The
equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977, H 9979, T 9063,
and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from June 1, 1998
through May 21, 2000. Some of these seat belt assemblies may have been installed as service
replacement equipment on the vehicles involved in there call. In the event of a collision, these seat
belts may not restrain an occupant increasing the risk of injury. Dealers will inspect these vehicles
and replace the Service Seat Belt Assemblies that were installed in these vehicles from January 1
through June 13, 2000. Owner notification is expected to begin during late July 2000. Owners who
take their vehicles to an authorized dealer on an agreed upon service date and do not receive the
free remedy within a reasonable time should contact Ford at1-800-392-3673. Also contact the
National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
1996 FORD CROWN VICTORIA
1996 LINCOLN TOWN CAR
1996 MERCURY GRAND MARQUIS
1997 FORD CROWN VICTORIA
1997 LINCOLN TOWN CAR
1997 MERCURY GRAND MARQUIS
1998 FORD CROWN VICTORIA
1998 LINCOLN TOWN CAR
1998 MERCURY GRAND MARQUIS
1999 FORD CROWN VICTORIA
1999 LINCOLN TOWN CAR
1999 MERCURY GRAND MARQUIS
2000 FORD CROWN VICTORIA
2000 LINCOLN TOWN CAR
2000 MERCURY GRAND MARQUIS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA00V157002 > Jun > 00 > Recall 00V157002:
Service Stock Seat Belt Assemblies
Seat Belt: All Technical Service Bulletins Recall 00V157002: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket front passenger side seat belt
assemblies that were sold by Ford Parts Departments from January 1, through June 13, 2000.
These seat belt assemblies fail to comply with the requirements of FMVSS No. 209, "Seat Belt
Assemblies." The equipment involved is Service Stock Seat Belt Assemblies, Model Nos. H 9977,
H 9979, T 9063, and T 9217, built by TRW Vehicle Safety Systems, Inc. (TRW) manufactured from
June 1, 1998 through May 21, 2000. Some of these seat belt assemblies may have been installed
as service replacement equipment on the vehicles involved in the recall. In the event of a collision,
these seat belts may not restrain an occupant increasing the risk of injury. Dealers will inspect
these vehicles and replace the Service Seat Belt Assemblies that were installed in these vehicles
from January 1 through June 13, 2000. Owner notification is expected to begin during late July
2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and
do not receive the free remedy within a reasonable time should contact Ford at1-800-392-3673.
Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at
1-888-DASH-2-DOT (1-888-327-4236).
1996 FORD CROWN VICTORIA
1996 LINCOLN TOWN CAR
1996 MERCURY GRAND MARQUIS
1997 FORD CROWN VICTORIA
1997 LINCOLN TOWN CAR
1997 MERCURY GRAND MARQUIS
1998 FORD CROWN VICTORIA
1998 LINCOLN TOWN CAR
1998 MERCURY GRAND MARQUIS
1999 FORD CROWN VICTORIA
1999 LINCOLN TOWN CAR
1999 MERCURY GRAND MARQUIS
2000 FORD CROWN VICTORIA
2000 LINCOLN TOWN CAR
2000 MERCURY GRAND MARQUIS
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Page 7679
Seat Belt: Specifications
Front retractor bolt ...............................................................................................................................
....................................................... 40 Nm (30 Lb-Ft) Rear retractor bolt ...........................................
............................................................................................................................................ 40 Nm (30
Lb-Ft) Front safety belt to floor pan .....................................................................................................
.................................................................. 40 Nm (30 Lb-Ft) Rear safety belt to floor pan bolt ..........
...................................................................................................................................................... 48
Nm (35 Lb-Ft) Rear safety belt buckle/buckle combination to floor pan bolt
..................................................................................................................... 48 Nm (35 Lb-Ft) Rear
safety belt buckle/belt combination to floor pan bolt
......................................................................................................................... 48 Nm (35 Lb-Ft)
Height adjuster bolt ..............................................................................................................................
...................................................... 40 Nm (30 Lb-Ft) Front safety belt buckle to seat nut
.............................................................................................................................................................
40 Nm (30 Lb-Ft) Front center safety belt to driver seat track nut
.......................................................................................................................................... 80 Nm (59
Lb-Ft) D-ring nut ..................................................................................................................................
................................................................. 40 Nm (30 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Page 7680
Seat Belt: Description and Operation
While the vehicle is in motion, the combination lap and shoulder belt adjusts to the occupant's
movement. However, if the vehicle is braked hard, cornered hard or if the vehicle receives an
impact of 8 km/h (5 mph) or more, the lap and shoulder belt locks and helps reduce the occupant's
forward movement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection
Seat Belt: Service and Repair Cleaning and Inspection
1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning
upholstery or carpets. Follow the instructions provided
with the soap.
WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7683
Seat Belt: Service and Repair Removal and Installation
Front Buckle End
Driver and Front Passenger Seat
1. Remove the front seat.
Driver Side Only
2. Disconnect the connector.
3. Remove the nut. 4. Remove the safety belt buckle through the seat cushion opening.
INSTALLATION
1. To install, reverse the removal procedure. 2. Make sure the center passenger restraint is
correctly routed through the seat cushion opening and is not twisted. Check the restraint system for
correct operation.
Height Adjuster-Front
REMOVAL
1. Remove the upper B-pillar.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7684
2. Remove the height adjuster.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Rear Seat Buckle End
REMOVAL
1. Remove the rear seat cushion.
2. Remove the buckle.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7685
1. To install, reverse the removal procedure. 2. Make sure the safety belt buckles are routed
correctly and are placed on the seat cushion. 3. Check the restraint system for correct operation.
Retractor and Tongue - Front Seats
REMOVAL
1. Remove the front door scuff plate.
2. Remove the rear door scuff plate.
3. Pull back the weatherstrips.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7686
4. Remove the cover.
5. Remove the bolt.
6. Remove the center body pillar lower finish panel.
7. Remove the cover.
8. Remove the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7687
9. Remove the screw.
10. Remove the retractor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7688
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Retractor and Tongue - Rear Seats
REMOVAL
1. Remove the package tray trim panel.
2. Remove the retractor.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Safety Belt-Front Center
REMOVAL
1. Remove the driver seat safety belt buckle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7689
2. Remove the front seat center safety belt.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7690
Seat Belt: Service and Repair Safety Belt Maintenance and Inspection
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar, if equipped), shoulder belt height adjuster (if equipped), child safety seat
tether bracket assemblies (if equipped) and attaching hardware should be inspected after any
collision. New safety belt assemblies should be installed unless a qualified technician finds that the
belts show no damage and operate correctly. Safety belt assemblies not in use during a collision
should also be inspected and new assemblies installed if either damage or incorrect operation is
noted.
1. The safety belt assemblies should be periodically inspected to make sure that they have not
become damaged and that they remain in correct
operating condition, particularly if they have been subjected to severe stress.
2. Before installing the new safety belt assembly; the safety belt retaining areas must be inspected
for damage and distortion. If the retaining points
are damaged and distorted, the sheet metal must be reworked back to its original shape and
structural integrity.
3. Install the new safety belt(s). 4. Carry out the Functional Test.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7691
Seat Belt: Service and Repair Service Procedures
Parts Replacement Chart
Code Letter ..........................................................................................................................................
.................................................................Part Name
1K ..................................................................................................................................................
Bolt-7/16-2 x 1.38 Pan Shoulder Tapping-0.50 Shoulder 1M ..............................................................
.............................................................................................................. Bolt-7/16-20 x 1.15 Pan
Head Tapping 1B
................................................................................................................................................
Bolt-7/16-20 x 1.15 Pan Shoulder Tapping-0.50 Shoulder 2Y ............................................................
...................................................................................................... Bolt-1/2-13 x 1.5 Pan Head
Shoulder Locking
Post Collision Inspection
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child safety seat
tether bracket assemblies (if equipped) and attaching hardware should be inspected after any
collision. New safety belt assemblies should be installed unless a qualified technician finds the
assemblies show no damage and operate correctly. Safety belt assemblies not in use during a
collision should also be inspected and new assemblies installed if either damage or incorrect
operation is noted.
1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected
for damage and distortion. If the attaching points are
damaged and distorted, the sheet metal must be worked back to its original shape and structural
integrity.
2. Install the new safety belt(s). 3. Carry out the Functional Test.
Safety Belt Tongue Rotated on Belt
1. Grasp the belt tongue and pull the belt webbing down to form a loop through the upper (longer
and narrower) slot in the tongue. 2. Rotate and fold the belt webbing over itself within the slot to
remove the twist. 3. Pull the excess belt webbing back through the upper slot in the belt tongue. 4.
Grasp the belt tongue and pull the belt webbing up to form a loop through the low slot in the
tongue.
5. Rotate and fold the belt webbing over itself within the slot to remove the twist.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7692
6. Pull the excess belt webbing through the slot. 7. The safety belt tongue should face inward when
completed.
Seat Belt With Anchor Plate Thread Damage
1. Remove the broken or stripped bolt.
NOTE: The lap/shoulder safety belts are factory-installed in their correct locations. If the safety
belts are removed for any reason, they must be installed. The 7/16 x 20 Torx (R) head anchor bolts
must be hand-started and then tightened to 40 Nm (30 lb-ft).
2. Drill out the internal threads in the safety belt anchor plate with a 27/64-inch drill. 3. Rethread the
anchor plate with a 1/2-13 tap. 4. Blow out the chips. 5. Install the attachment parts in the correct
sequence. For additional information, refer to Safety Belt Buckle-Front or Safety Belt Buckle-Rear.
Install a new bolt, hand-tighten and then tighten the bolt to 40 Nm (30 lb-ft).
NOTE: Refer to the Parts Replacement Chart when installing new parts.
Seat Belt Without Anchor Plate Thread Damage
The seat and shoulder safety belts are factory-installed in their proper locations. If the belts are
removed for any reason, they MUST be installed. The 7/16-inch x 20 TORX (R) head anchor bolts
must be hand-started and then tightened to 40 Nm (30 lb-ft).
1. Remove damaged bolt from anchor reinforcement and discard. 2. Install a new bolt by hand.
Tighten to 40 Nm (30 lb-ft).
Shoulder Strap Adjuster With Stripped Weld Nuts, Front Seat
D - Ring Installation Kit
Special Tool(s)
1. Remove the shoulder safety belt height adjuster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7693
2. Use the one-half inch drill provided in the special tool kit to drill out the damaged threads in the
upper pillar structure.
3. Apply a suitable lubricant to the M14 x 1.5 tap provided in the special tool kit and tap new
threads.
NOTE: After each rotation, back off the tap slightly to remove the new cuttings and be sure to blow
out any chips before proceeding.
4. Use a threaded insert provided in the special tool kit and screw it into the retapped hole until it is
slightly below the surface.
5. Use a hammer to tap the installation tool provided in the special tool kit several times to seat the
insert keys.
NOTE: Refer to Height Adjuster-Front if the two bolts on the height adjuster are not stripped. If the
bolts are stripped, install a new height adjuster.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7694
6. Insert the shoulder safety belt height adjuster in the opening of the upper B-pillar structure,
making sure the shoulder belt height adjuster knob on
the shoulder safety belt height adjuster is positioned above the D-ring attachment nut. (The tab is
located at the top and is to be inserted in the hole provided in the B-pillar structure).
NOTE: If the two Torx (R) head retaining bolts on the shoulder safety belt height adjuster are not
stripped, install the shoulder safety belt height adjuster to the body structure as stated in this step.
If the front seat shoulder strap adjuster retaining bolts are stripped, install a new shoulder safety
belt height adjuster.
7. Hand tighten the bolts until they are snug.
8. Tighten the bolts. 9. Install the B-pillar trim.
10. Operate the front seat shoulder strap adjuster. Make sure it travels from top to bottom and
locks correctly in each position.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Cleaning and Inspection > Page 7695
11. Install the safety belt D-ring and tighten the nut. 12. Install the D-ring cover. Make sure the
safety belt D-ring rotates freely. 13. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Description and Operation
Seat Belt Buckle: Description and Operation
The inboard front safety belt buckle end-LH, front safety belt buckle end RH is secured to the front
seat track. The center safety belt is attached to the floor pan through a slot in the seat track.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Buckle End - Rear Seats
Seat Belt Buckle: Service and Repair Buckle End - Rear Seats
REMOVAL
1. Remove the rear seat cushion.
2. Remove the buckle.
INSTALLATION
1. To install, reverse the removal procedure. 2. Make sure the safety belt buckles are routed
correctly and are placed on the seat cushion. 3. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Buckle End - Rear Seats > Page 7701
Seat Belt Buckle: Service and Repair Buckle End - Front Seats
Driver and Front Passenger Seat
1. Remove the front seat.
Driver Side Only
2. Disconnect the connector.
3. Remove the nut. 4. Remove the safety belt buckle through the seat cushion opening.
INSTALLATION
1. To install, reverse the removal procedure. 2. Make sure the center passenger restraint is
correctly routed through the seat cushion opening and is not twisted. Check the restraint system for
correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Description and Operation
Seat Belt Extension: Description and Operation
A safety belt that is too short even when fully extended can be lengthened. The safety belt
extension is available. This assembly will add approximately 20 cm (8 inches) to the length of the
safety belt. Use the safety belt extension only if the safety belt is too short when fully extended. Do
not use the safety belt extension to alter the fit of the shoulder belt across the torso. Safety belt
extensions are available at no cost from any authorized Ford or Lincoln-Mercury dealer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Specifications
Seat Belt Height Adjuster: Specifications
Description ...........................................................................................................................................
............................................................ N.m (Lb-Ft)
Front Seat Shoulder Strap Adjuster Bolt
.................................................................................................................................................... 40
Nm (30 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Specifications > Page 7708
Seat Belt Height Adjuster: Service and Repair
REMOVAL
1. Remove the upper B-pillar.
2. Remove the height adjuster.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Fasten Belts Indicator <--> [Seat Belt Reminder Lamp]
> Component Information > Description and Operation
Fasten Belts Indicator: Description and Operation
The safety belt indicator is directly hardwired to the Lighting Control Module (LCM). The LCM
controls the safety belt indicator depending on the signal it receives from the safety belt buckle
switch. The safety belt indicator illuminates when the safety belt is not buckled, closing the safety
belt buckle switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement
Technical Service Bulletin # 00S15 Date: 000901
Recall - Seat Belt Retractor Inspection/Replacement
SAFETY RECALL 00S15
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and,
if Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7720
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7721
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7722
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions of Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7723
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7724
Table 1 * # 150 * Crown Victoria/Grand Marquis
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7725
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7726
Table 2 **150* Town Car
DEALER PRICE For latest prices, refer to:
^ DOES II
^ Updated Price Book
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7727
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
LEFT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front left-hand seat belt retractor. The build label is located at one of two possible places on the
seat belt webbing. Some minor disassembly may be required to access the build label. An affected
seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected
by the build date will be replaced. Follow the appropriate procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7728
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7729
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7730
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7731
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7732
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7733
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor
Inspection/Replacement > Page 7734
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement
Technical Service Bulletin # 00S16 Date: 000901
Recall - Seat Belt Inspection/Replacement
00S16 SAFETY RECALL
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection
and, If Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7739
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7740
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7741
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions on Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7742
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7743
Table 1 * # 150 * Crown Victoria/Grand Marquis
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7744
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7745
Table 2 * # 150 * Town Car
DEALER PRICE For latest prices refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
RIGHT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front right-hand seat belt retractor. The build label is located at one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7746
of two possible places on the seat belt webbing. Some minor disassembly may be required to
access the build label. An affected seat belt retractor will be identified by the build date. Only a seat
belt retractor determined affected by the build date will be replaced. Follow the appropriate
procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7747
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7748
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7749
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7750
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7751
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7752
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt
Inspection/Replacement > Page 7753
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement
Technical Service Bulletin # 00S15 Date: 000901
Recall - Seat Belt Retractor Inspection/Replacement
SAFETY RECALL 00S15
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Left Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor inspection and,
if Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7759
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7760
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of Lip to $1,100 per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7761
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions of Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7762
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7763
Table 1 * # 150 * Crown Victoria/Grand Marquis
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7764
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7765
Table 2 **150* Town Car
DEALER PRICE For latest prices, refer to:
^ DOES II
^ Updated Price Book
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7766
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
LEFT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front left-hand seat belt retractor. The build label is located at one of two possible places on the
seat belt webbing. Some minor disassembly may be required to access the build label. An affected
seat belt retractor will be identified by the build date. Only a seat belt retractor determined affected
by the build date will be replaced. Follow the appropriate procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7767
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7768
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7769
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7770
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7771
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7772
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat
Belt Retractor Inspection/Replacement > Page 7773
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement
Technical Service Bulletin # 00S16 Date: 000901
Recall - Seat Belt Inspection/Replacement
00S16 SAFETY RECALL
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which
Had the Right Front Safety Belt Retractor Replaced in Service - Safety Belt Retractor Inspection
and, If Necessary, Replacement
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7778
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7779
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any
outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of
this requirement by a dealer could result in a civil penalty of up to $1,1OO per vehicle.
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated
Communicator (FDCC) and other eligible vehicles, which are brought to your dealership.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7780
DEALER-OWNER CONTACT
Owners of affected vehicles according to Ford Motor Company records will be notified with the
owner letter as shown. If you have knowledge of an owner with an affected vehicle that did not
receive a notification letter, contact that owner, give the owner a copy of the owner letter and
arrange for a service date.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
REGIONAL CONTACT Advise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the
instructions on Attachment IV.
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel,
which will be at the owner's expense. Rentals should be provided only while the vehicle is at the
dealership for the safety belt replacement. Follow Extended Service Plan (ESP) guidelines for
rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in
the Miscellaneous Expense area of the recall claim.
NOTE:
Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before
calling Town Car owners, review Attachment IV to familiarize yourself with this special handling
procedure.
PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention
and Return Procedures".
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7781
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing channels as noted below:
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7782
Table 1 * # 150 * Crown Victoria/Grand Marquis
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7783
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7784
Table 2 * # 150 * Town Car
DEALER PRICE For latest prices refer to:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
RIGHT FRONT SAFETY BELT RETRACTOR
OVERVIEW This procedure will require the technician to locate and inspect the build label for the
front right-hand seat belt retractor. The build label is located at one
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7785
of two possible places on the seat belt webbing. Some minor disassembly may be required to
access the build label. An affected seat belt retractor will be identified by the build date. Only a seat
belt retractor determined affected by the build date will be replaced. Follow the appropriate
procedure in the workshop manual.
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the
anchor boot.
1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows:
^ Look for the build label on the webbing directly above the anchor boot. If the build label is located
here proceed to Label Inspection. If the label is not located here proceed to the next bullet point.
See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7786
^ Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the
rubber washer to allow the bolt to come off, then slide the anchor boot off of the webbing. The build
label is folded and sewn into the webbing. See Figures 2 and 3. Proceed to Label Inspection.
LABEL INSPECTION
1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date
Code Translator chart to determine the build date.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7787
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R)
and must be replaced.
a. If you have determined the seat belt must be replaced based on the build date, replace the seat
belt retractor following the service procedures in Section 01-20A or 501-20A of the appropriate
workshop manual.
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected
vehicles have been reworked to include a stowage clip. Retractors with stowage clips are
acceptable regardless of date code.
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if
disassembly is required) as follows:
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the
anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7788
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7789
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7790
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7791
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat
Belt Inspection/Replacement > Page 7792
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 7793
Seat Belt Retractor: Specifications
Description ...........................................................................................................................................
............................................................ N.m (Lb-Ft)
Front retractor bolt ...............................................................................................................................
....................................................... 40 Nm (30 Lb-Ft) Rear retractor bolt ...........................................
............................................................................................................................................ 40 Nm (30
Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 7794
Seat Belt Retractor: Description and Operation
WARNING: Rear-facing infant seats should never be placed in the front seats.
The dual locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety
belt for the front seat passenger, rear seat outboard passengers and rear center passenger
operates in two ways:
1. In the vehicle-sensitive (emergency locking) mode, the shoulder belt retractor will allow the
occupant freedom of movement, locking tight only on
hard braking, hard cornering or impacts of approximately 8 km/h (5 mph) or more. The front and
rear outboard seat belt retractors can also be made to lock by pulling/jerking on the belt.
2. In the automatic locking mode, the shoulder belt retractor will be automatically locked and
remain locked when the combination lap/shoulder
safety belt is buckled and does not allow the occupant freedom of movement. This mode provides
tight lap/shoulder belt fit on the occupant and on a child safety seat or infant carrier installation
restraint.
When the combination lap/shoulder belt is unbuckled and allowed to retract completely, the
retractor will switch to the vehicle sensitive (emergency locking) mode.
The automatic locking mode must be used when installing a child safety seat on the front
passenger seat and rear outboard seats where dual locking retractors are provided.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Seat Belt, Retractor and Tongue
Seat Belt Retractor: Service and Repair Front Seat Belt, Retractor and Tongue
REMOVAL
1. Remove the front door scuff plate.
2. Remove the rear door scuff plate.
3. Pull back the weatherstrips.
4. Remove the cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7797
5. Remove the bolt.
6. Remove the center body pillar lower finish panel.
7. Remove the cover.
8. Remove the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7798
9. Remove the screw.
10. Remove the retractor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7799
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7800
Seat Belt Retractor: Service and Repair Rear Seats
REMOVAL
1. Remove the package tray trim panel.
2. Remove the retractor.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Description and Operation
Seat Belt Warning Timer: Description and Operation
The safety belt warning indicator light illuminates and a chime sounds to remind the occupants to
fasten their safety belts.
The conditions of operation for the safety belt warning indicator and chime are as follows:
- If the driver safety belt is not buckled before the ignition switch is turned to ON, then the safety
belt warning indicator illuminates for one to two minutes and the warning chime sounds for four to
eight seconds.
- If the driver safety belt is buckled while the warning indicator is illuminated and the reminder
chime is sounding, then the safety belt warning indicator and reminder chime turn off.
- If the driver safety belt is buckled before the ignition switch in turned to ON, then the safety belt
warning indicator and reminder chime remain off.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Specifications
Impact Sensor: Specifications
Air bag Electronic Crash Sensor (ECS) module bolts
.................................................................................................................................. 12 Nm (9 Lb-Ft)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Specifications > Page 7808
Impact Sensor: Service Precautions
WARNING:
- Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag
Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Specifications > Page 7809
Impact Sensor: Service and Repair
REMOVAL
WARNING:
- Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag
Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To avoid accidental deployment and possible personal injury, the backup power supply must be
depleted before repairing or replacing any front or side air bag supplemental restraint system
(SRS) components and before servicing, replacing, adjusting or striking components near the front
or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and
hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator upper
sight shield.
3. Remove the air bag sensor.
1 Disconnect the air bag sensor electrical connector.
2 Remove the three screws.
3 Remove the air bag sensor.
INSTALLATION
1. Follow the removal procedure in reverse order.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Specifications > Page 7810
auxiliary batteries and power supplies (if equipped).
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
Antenna: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
TSB 04-24-5
12/13/04
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR
FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria,
Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005
Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape
2004-2005 F-150, Freestar 2005 Escape Hybrid
LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator
2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego
1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 04-18-9 to update vehicle applications and service procedure.
ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid
lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the
rear window glass.
ACTION Follow the diagnostic and repair procedures included in this article to inspect and service
rear defroster grid lines, integral antenna concerns or broken terminal tabs.
SERVICE PROCEDURE
Warrantable/Non Warrantable repairs
Warrantable grid line repairs typically can be identified by one inoperative grid line with a small
discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are
scratched or have the silver material removed are not warrantable and should be addressed with
the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable
repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated
Back Lite Damageability Job Aid for additional information and examples of defects and damage.
NOTE
THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE
GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY
APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7816
THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS
EXPLAINED IN THIS ARTICLE.
Examples Of Non-Warrantable Grid Line Damage
^ Ice scraper damage to grid lines
^ Animal scratches on grid lines
^ Window tint film/removal of the film which damages grid lines
^ Stickers placed over grids which upon removal, removes the grid line material
^ License plate (steel type placed against the inside of back glass) which rubs on the grid line
causing damage
^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal
removes grid line material
^ Cargo or lumber rubbing against the glass which removes grid line material
^ Cellular phone antenna installation/removal which damages grid line material
NOTE
AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE
SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL
ACROSS THEM.
GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL
IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON
THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR
12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID
LINE INOPERATIVE - DIAGNOSTICS
1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power
and ground to the back-glass.
2. Connect a test lamp or DVOM to a good body ground.
3. Turn the ignition key to the run position and depress and release the rear defroster button to turn
the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME
THE DEFROSTER BUTTON IS PRESSED.
4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM +
lead to each grid line. (Use caution not to damage grid lines). The DVOM should read
approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test
light, the bulb should be approximately the same brightness on each line from top to bottom. If the
DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid
line with the + test lead or test lamp until the voltage changes suddenly. This is the area of
concern, use chalk to mark the area of concern and mark the outside of the glass at that same
area.
5. Repair per the Grid Line Repair Procedure.
GRID LINE REPAIR PROCEDURE
NOTE
LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE,
HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS
TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE
(5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING
DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER
THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND
EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT
VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID
LINE AREAS.
NOTE
IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY
RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT
FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND
SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW
DEFROSTER REPAIR COMPOUND.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7817
Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or
equivalent meeting Ford specification ESB-M4J58-A as follows:
Surface Preparation
1. Bring vehicle inside and warm it to 60° F (16° C) or above.
2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of
the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service
area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry.
NOTE
THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE
PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME.
Mixing
The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at
room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake
frequently during use.
Application
1. Mark location of open grid on the outside of the back window glass (performed in diagnostics).
Place protective covering over the package tray as necessary.
2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is
best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should
be at the center of the mask and tape gap must be no wider than the existing grid line. Other types
of tape may be used but end results of the repair may not appear as visually acceptable due to
ease of application and tape edge finish.
3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound
to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five
(5) minutes drying time between coats) across the open grid line area using the brush applicator in
the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area.
Apply a minimum of six (6) coats of the grid repair compound.
4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown
lacquer touch-up paint across the open line area first. Take care to paint only the area missing the
color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at
least five (5) minutes between coats. Apply six (6) coats of grid repair compound.
NOTE
THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER
TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE
REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7818
TIME TO MATCH THE REST OF THE GRID.
5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step
outside and inspect the repaired area. If the repair compound is visible above or below the grid, the
excess can be removed. This may be done by placing a single-edge razor blade on the back
window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better
but may not be cosmetically appealing.
CAUTION
BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID
LINES FUNCTION PROPERLY WHEN FINISHED.
Curing
The service coating will air-dry in approximately one (1) minute and the system can be energized
after five minutes. Maximum hardness and adhesion occur after approximately 24 hours.
SOLDER METHOD OF LEAD TERMINAL
NOTE
THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE.
PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY.
The new terminal will cover the original terminal location, but must be placed so that the new
terminal conductive areas will be placed on a good conductive base. This area should be cleaned
with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be
cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous
polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to
improve appearance.
CAUTION
DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS
PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE
EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY
AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER.
BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN
CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT
TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL.
The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a
visual indication when the terminal has reached the proper temperature to melt the solder on the
terminal. When the proper temperature is achieved the temperature paint will liquefy and change
color.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7819
Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus,
use type B (Figure 3).
NOTE
DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS
COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL.
SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL
ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR
MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE
ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE
BUSS-BAR ON GOOD CONDUCTIVE MATERIAL.
1. Place the replacement terminal over the original tab location making sure the conductive areas
of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original
location which does not have conductive material (figure 4).
2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the
terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle
may allow the terminal to slip when the solder liquefies).
3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab.
Energize the soldering gun and watch for the painted area of the terminal to liquefy and change
color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint
color completely changes on either side of the terminal, de-energize the soldering gun and
continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30)
seconds.
4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool
for another two (2) minutes before the wiring lead is attached to the terminal.
5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify
operation.
Parts Block
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 7820
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042405A Repair Grid Lines (Includes 0.7 Hr.
Time To Diagnose And Recheck)
042405B Replace Terminal (Includes 0.4 Hr.
Time To Diagnose And Recheck)
042405C Repair Grid Lines And 0.8 Hr.
Replace Terminal (Includes Time To Diagnose And Recheck)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7042006 28
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > Page 7821
Antenna: Specifications
Antenna Isolator Module Nuts 10 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > Page 7822
Antenna: Description and Operation
The antenna is concealed on the inside of the rear window glass. The AM antenna consists of the
rear window defroster grid and the FM antenna is the conductive tracing above the rear window
defroster grid.
The radio antenna uses an antenna isolator module mounted under the rear package tray trim
panel to separate the AM signals, FM signals, and rear defroster power.
The radio antenna uses a two-piece coaxial cable to connect the radio chassis to the antenna
isolator module. The front antenna lead-in cable is connected to the audio unit and has an in-line
connector at the right end of the instrument panel. The rear antenna cable connects at the right end
of the instrument panel and runs along the rocker panel within the body main wiring harness. It
separates from the harness at the quarter panel and runs behind
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service
Bulletins > Page 7823
the rear seat and up to the package tray where it connects to the antenna isolator module. A third
coaxial cable connects the FM antenna to the antenna isolator module along the right side of the
rear window.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna
Antenna: Service and Repair Antenna
1. The antenna is integral to the back window glass and can be repaired, but not replaced
separately.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7826
Antenna: Service and Repair Antenna - Grid Wire Repair
Special Tools
Special Tool(s)
NOTE: Any breaks longer than 25.4 mm (1 in) in one grid cannot be repaired. The back window
glass must be replaced. Breaks equal to or shorter than 25.4 mm (1 in) in the heated back window
grid wire can be successfully repaired by using the following procedure:
1. Obtain the following repair kit:
^ Repair Kit Order Number 50-25-0584-0029.
2. The vehicle should be brought inside and allowed to reach 16°C (60°F) or above. 3. Clean the
repair area with denatured alcohol.
4. Place the grid line mask over the break aligning the cut out slots on either side of the repair area.
5. Apply the epoxy to the repair area. 6. Remove the mask without disturbing the epoxy. 7. Use
Heat Gun to heat the repair area for one to two minutes at a distance of about 25-50 mm (1-2 in).
This procedure should heat the repair area
to approximately 149°C (300°F).
8. The heated back window may be energized immediately after the repair. Optimum hardness and
adhesion will occur after 24 hours. Do not disturb
the repaired area until that time.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7827
Antenna: Service and Repair Antenna - Isolator Module
REMOVAL
1. Remove the rear package tray trim. 2. Remove the roof side rear trim panels.
3. Position the AM antenna/rear window defroster cable aside.
1 Disconnect the electrical connectors.
2 Unclip the wire retainers.
3 Position the AM antenna/rear window defroster cable aside.
4. Remove the antenna isolator module nuts.
5. Remove the antenna isolator module.
1 Disconnect the electrical connector.
2 Disconnect the antenna cables.
3 Remove the antenna isolator module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7828
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7829
Antenna: Service and Repair Cable - Antenna Lead In, Front
REMOVAL
1. Remove the audio unit.
2. Disengage the antenna cable guide.
3. Position the RH lower instrument panel insulator aside.
1 Remove the pin-type retainers.
2 Release the locking tab.
3 Remove the instrument panel lower insulator.
^ Disconnect the courtesy lamp.
4. Disconnect the radio antenna lead in-cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7830
5. Remove the antenna cable bracket screw.
6. Remove the center carpet insert.
1 Remove the two pin-type retainers.
2 Remove the center carpet insert.
7. Remove the antenna lead-in cable.
1 Remove the three clips.
2 Remove the antenna lead-in cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7831
Antenna: Service and Repair
Antenna
1. The antenna is integral to the back window glass and can be repaired, but not replaced
separately.
Antenna - Grid Wire Repair
Special Tools
Special Tool(s)
NOTE: Any breaks longer than 25.4 mm (1 in) in one grid cannot be repaired. The back window
glass must be replaced. Breaks equal to or shorter than 25.4 mm (1 in) in the heated back window
grid wire can be successfully repaired by using the following procedure:
1. Obtain the following repair kit:
^ Repair Kit Order Number 50-25-0584-0029.
2. The vehicle should be brought inside and allowed to reach 16°C (60°F) or above. 3. Clean the
repair area with denatured alcohol.
4. Place the grid line mask over the break aligning the cut out slots on either side of the repair area.
5. Apply the epoxy to the repair area. 6. Remove the mask without disturbing the epoxy. 7. Use
Heat Gun to heat the repair area for one to two minutes at a distance of about 25-50 mm (1-2 in).
This procedure should heat the repair area
to approximately 149°C (300°F).
8. The heated back window may be energized immediately after the repair. Optimum hardness and
adhesion will occur after 24 hours. Do not disturb
the repaired area until that time.
Antenna - Isolator Module
REMOVAL
1. Remove the rear package tray trim. 2. Remove the roof side rear trim panels.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7832
3. Position the AM antenna/rear window defroster cable aside.
1 Disconnect the electrical connectors.
2 Unclip the wire retainers.
3 Position the AM antenna/rear window defroster cable aside.
4. Remove the antenna isolator module nuts.
5. Remove the antenna isolator module.
1 Disconnect the electrical connector.
2 Disconnect the antenna cables.
3 Remove the antenna isolator module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7833
Cable - Antenna Lead In, Front
REMOVAL
1. Remove the audio unit.
2. Disengage the antenna cable guide.
3. Position the RH lower instrument panel insulator aside.
1 Remove the pin-type retainers.
2 Release the locking tab.
3 Remove the instrument panel lower insulator.
^ Disconnect the courtesy lamp.
4. Disconnect the radio antenna lead in-cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7834
5. Remove the antenna cable bracket screw.
6. Remove the center carpet insert.
1 Remove the two pin-type retainers.
2 Remove the center carpet insert.
7. Remove the antenna lead-in cable.
1 Remove the three clips.
2 Remove the antenna lead-in cable.
INSTALLATION
1. To install, reverse the removal procedure.
Cable - Antenna Lead In, Rear
REMOVAL
CAUTION: The antenna lead-in cable is not removable from the wiring harness. If the cable needs
to be replaced, leave it in the wiring harness. Install a new cable on top of the body main wiring
harness and secure it with wire ties. Do not cut into the wiring harness to remove the existing
antenna lead-in cable.
1. Disconnect the battery ground cable. 2. Remove the package tray trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7835
3. Remove the roof side rear trim panels.
4. Remove the RH front and rear scuff plates.
NOTE: RH front shown, all others similar.
5. Remove the lower quarter trim panel.
6. Remove the B-pillar trim panel.
7. Remove the RH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Release the locking tab.
3 Remove the instrument panel lower insulator.
^ Disconnect the courtesy lamp.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7836
8. Remove the A-pillar lower trim panel.
9. Disconnect the radio antenna lead-in cable.
10. Disconnect the radio antenna lead-in cable.
INSTALLATION
CAUTION: The antenna lead-in cable is not removable from the wiring harness. If the cable needs
to be replaced, leave it in the wiring harness. Install a new cable on top of the body main wiring
harness and secure it with wire ties. Do not cut into the wiring harness to remove the existing
antenna lead in cable. Tie back or insulate the old cable ends to keep them from causing noise.
1. Connect the antenna lead-in cable at the antenna isolator module.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7837
2. Install the new antenna lead-in cable on top of the old one and secure it with wire ties.
3. Install the new antenna lead-in cable in the wiring harness conduit along the rocker panel.
4. Connect the antenna lead-in cable.
5. Install the A-pillar lower trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7838
6. Install the instrument panel lower insulator.
1 Position the RH instrument panel lower insulator.
2 Engage the locking tab.
3 Install the pin-type retainers.
^ Connect the courtesy lamp.
7. Install the B-pillar trim.
8. Install the lower quarter trim panel.
9. Install the scuff plates
10. In stall the roof side rear trim panels. 11. Install the package tray trim panel. 12. Connect the
battery ground cable.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 7839
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Cable - Isolator Module to FM Antenna
REMOVAL
1. Remove the rear package tray trim. 2. Remove the RH roof side rear trim panel. 3. Position
sound insulator aside.
4. Disconnect the antenna cable.
5. Position the headliner aside.
1 Remove the pin-type retainers.
2 Position the headliner aside.
6. Remove the antenna lead-in cable.
1 Disconnect the connector.
2 Remove the bolt.
3 Disconnect the cable retainers and remove the antenna lead-in cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 7845
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS)
Alarm Module: Service and Repair Module - Passive Anti-Theft System (PATS)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION ^
Prior to removal of module, it is necessary to upload module configuration information to New
Generation STAR (NGS) Tester. This information needs to be downloaded in to the new module
once installed.
^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may
result.
2. Remove the LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the LH instrument panel insulator.
3. Remove the lower steering column cover.
1 Remove the screws.
2. Remove the lower steering column cover.
4. Remove the lower steering column cover reinforcement
1 Remove the screws.
2 Remove the lower steering column cover reinforcement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7848
5. Remove the Passive Anti-Theft System (PATS) module and bracket.
1 Remove the bolts.
2 Disconnect the electrical connector.
INSTALLATION
1. To install,reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
^ Prior to starting the vehicle, check for PATS Diagnostic Trouble Codes (DTCs). Perform the
appropriate pinpoint test.
^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory.
Insert each key in the ignition and turn to RUN for automatic programming.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7849
Alarm Module: Service and Repair Module - Passive Anti-Theft Transceiver
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Twist the tilt wheel handle and shank and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the lower steering column shroud.
3 Remove the upper steering column shroud.
NOTE: The steering wheel has been removed for clarity.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7850
5. Remove LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the insulator.
6. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
7. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
8. Remove the transceiver assembly.
1 Remove the screw.
2 Release the transceiver over the rib on the lock cylinder housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Service and Repair > Module - Passive Anti-Theft System (PATS) > Page 7851
NOTE: Only apply pressure below the key cylinder rib.
3 Disconnect the electrical connector locator and electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
^ No key replacement or re-initialization needs to occur with the removal or installation of a new
PATS transceiver.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Diagrams > Page 7856
Keyless Entry Key-Pad: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door panel. 3. Position weathershield aside.
4. Remove the keyless entry keypad.
1 Remove the Clip.
^ Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair
Keyless Entry Transmitter: Service and Repair
1. Cycle the ignition from OFF to RUN four times within three seconds. The locks will then lock and
unlock, confirming program mode has been
entered.
2. Press any button on the transmitter to be programmed.
NOTE: When the first keyless entry remote transmitter is programmed, all other keyless entry
remote transmitters are erased.
3. If additional keyless entry remote transmitters are to be programmed, repeat step 2 within 7.5
seconds. 4. To exit program mode, turn the ignition to START or wait 7.5 seconds.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Description and Operation
Garage Door Opener Transmitter: Description and Operation
The HomeLink(R) universal transmitter provides a convenient way to replace up to three hand-held
transmitters with a single built-in device. The universal transmitter:
^ will operate garage doors, gates and home/office lighting and security Systems.
^ will actually learn and transmit the radio frequency of up to three hand-held transmitters from any
of the systems mentioned above.
^ is an integral part of the left sun visor assembly and is powered by the vehicle battery and
charging system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Flow of Diagnosis
Garage Door Opener Transmitter: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged universal transmitter
^ Damaged receiver
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Flow of Diagnosis > Page 7865
Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged universal transmitter
^ Damaged receiver
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Flow of Diagnosis > Page 7866
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Flow of Diagnosis > Page 7867
A1 - A2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Programming
Garage Door Opener Transmitter: Service and Repair Programming
WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE
ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL
SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT
USE THIS HOMELINK(R) TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS
STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS
INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1,
1982. FOR MORE INFORMATION, CALL HOMELINK(R) CUSTOMER ASSISTANCE AT
1-800-355-3515.
1. Verify the hand-held transmitter is operative.
CAUTION: During this procedure, the system that you are programming will be made to operate.
Make sure that people or objects are clear of the garage door or gate being programmed.
2. Prepare for programming the universal transmitter by erasing all three channels by holding down
the two outside buttons until the red light begins
to flash (20-30 seconds). Release both buttons.
3. Select one of the three universal transmitter channels to be programmed by pressing the desired
button. 4. Hold the end of the hand-held transmitter from the front surface of the universal
transmitter so that the red light can still be seen.
5. Use both hands to press the hand-held transmitter button and the desired button on the
universal transmitter. Do not release either button.
NOTE: During programming, the hand-held transmitter may automatically stop transmitting after
two seconds, which may not be long enough to program the universal transmitter. If programming
this type of hand-held transmitter, continue to hold the button on the universal transmitter while
re-pressing the hand-held transmitter button every two seconds (Canada only).
6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and
then rapidly. Release both buttons when the rapid
flashing begins. The universal transmitter has successfully learned the new frequency signal and
can be used in place of the hand-held transmitter(s).
7. To operate, simply press the appropriate button on the universal transmitter. The red light is on
while the signal is being transmitted.
NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open
the garage door, the garage door opener may have a "code protected" or "rolling code" feature.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Programming > Page 7870
Garage Door Opener Transmitter: Service and Repair Training A Garage Door Opener Equipped
With "Rolling Codes"
Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held
transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the
universal transmitter.
1 Remove the cover panel from the garage door opener receiver.
2 Locate the training button on the garage door opener receiver. Location and color of the button
may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual
or call HomeLink(R) customer assistance at 1-800-355-3515.
3 Press the training button on the garage door opener receiver for 1-2 seconds.
4 Press the programmed universal transmitter button for as long as the universal transmitter red
light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal
transmitter is trained to the receiver.
5 The garage door opener should recognize the universal transmitter.
Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons
until the red light begins to flash (20-30 seconds). Release both
buttons.
NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for
programming.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General
Module] > Component Information > Description and Operation
Multifunction Electronic Control Module: Description and Operation
The multifunction modules consist of the following:
^ Air Suspension Control Module
^ Driver Door Module (DDM)
^ Lighting Control Module (LCM)
The air suspension control module is linked to its own Data Link Connector (DLC). The air
suspension control module controls the air suspension and the Electronic Variable Orifice (EVO)
steering.
The Driver Door Module (DDM) is connected on the International Standards Organization (ISO)
9141 communication network. The DDM controls many functions including power windows, power
door locks and remote keyless entry.
The Lighting Control Module (LCM) is connected on the ISO 9141 communication network. The
LCM controls both interior and exterior lighting, back lighting, the battery saver and warning
chimes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General
Module] > Component Information > Description and Operation > Page 7874
Multifunction Electronic Control Module: Testing and Inspection
For Air Suspension concerns, See: Steering and Suspension/Suspension/Suspension Control (
Automatic - Electronic )
For Electronic Variable Orifice (EVO) Steering concerns,
For Warning Chime concerns, See: Instrument Panel, Gauges and Warning Indicators/Audible
Warning Device
For Lighting concerns, See: Lighting and Horns
For Power Window or Defroster concerns, See: Windows and Glass
For Power Door Lock concerns, See: Antitheft and Alarm Systems/Keyless Entry
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General
Module] > Component Information > Service and Repair > Air Suspension Module
Multifunction Electronic Control Module: Service and Repair Air Suspension Module
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Lower the instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Lower the instrument panel lower insulator.
3. Remove the instrument panel lower insulator.
1 Disconnect the power point electrical connector.
2 Remove the footwell lamp.
3 Remove the instrument panel lower insulator.
4. Remove the air suspension module.
1 Disconnect the electrical connectors.
2 Remove the air suspension module.
^ Release the spring clips to remove the module from the bracket.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General
Module] > Component Information > Service and Repair > Air Suspension Module > Page 7877
Multifunction Electronic Control Module: Service and Repair Driver Door Module
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General
Module] > Component Information > Service and Repair > Air Suspension Module > Page 7878
Multifunction Electronic Control Module: Service and Repair Lighting Control Module
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the LH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Disconnect the courtesy lamp.
3 Remove the LH instrument panel insulator.
3. Position the LCM aside.
1 Remove the locking tab.
2 Release the locking tab.
3 Position the LCM aside.
4. Remove the LCM.
1 Disconnect the electrical connectors.
2 Remove the LCM.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General
Module] > Component Information > Service and Repair > Air Suspension Module > Page 7879
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from New Generation STAR (NGS) Tester into the new module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > CD Changer > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > CD Changer > Component Information > Diagrams > Page 7888
CD Changer: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. If equipped, position the luggage compartment cover
aside.
3. Remove the digital audio compact disc changer.
1 Remove the bolt.
2 Remove the nuts.
3 Disconnect the electrical connector.
4. Remove the digital audio compact disc changer brackets.
^ Remove the six bolts and two brackets.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7898
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7899
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7900
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7901
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7902
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7903
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7904
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio
Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7910
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7911
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7912
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7913
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7914
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7915
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 7916
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers
Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7925
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7926
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7927
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7928
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7929
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7930
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 7931
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers
Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7937
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7938
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7939
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7940
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7941
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7942
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 7943
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 7944
Speaker: Description and Operation
There are two speaker Systems available:
^ premium sound system
^ base sound system
The premium sound speaker system has one speaker mounted in each front door and two
speakers mounted in the package tray.
The speakers consist of:
^ radio speaker (rear base and premium)
^ radio speaker (front base and premium)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted
Speaker: Service and Repair Door Mounted
REMOVAL
1. Remove the front door trim panels.
2. Remove the radio speakers.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the radio speakers.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted > Page 7947
Speaker: Service and Repair Package Tray Speaker
REMOVAL
1. Remove the package tray trim panel.
2. Remove the radio speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the radio speaker from the speaker cover.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player >
Component Information > Service and Repair
Tape Player: Service and Repair
1. For best performance, it is recommended that the tape player be cleaned once for every 10 to 12
hours of playing time. The tape player should be
cleaned using a Ford tape player cleaning cartridge, available at your Ford or Lincoln-Mercury
Dealer. The use of other cleaning products is not recommended, as these products could cause
damage to the player or cassette tapes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page
7956
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive
Anti-Theft System (PATS)
Alarm Module: Service and Repair Module - Passive Anti-Theft System (PATS)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION ^
Prior to removal of module, it is necessary to upload module configuration information to New
Generation STAR (NGS) Tester. This information needs to be downloaded in to the new module
once installed.
^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may
result.
2. Remove the LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the LH instrument panel insulator.
3. Remove the lower steering column cover.
1 Remove the screws.
2. Remove the lower steering column cover.
4. Remove the lower steering column cover reinforcement
1 Remove the screws.
2 Remove the lower steering column cover reinforcement.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive
Anti-Theft System (PATS) > Page 7959
5. Remove the Passive Anti-Theft System (PATS) module and bracket.
1 Remove the bolts.
2 Disconnect the electrical connector.
INSTALLATION
1. To install,reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
^ Prior to starting the vehicle, check for PATS Diagnostic Trouble Codes (DTCs). Perform the
appropriate pinpoint test.
^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory.
Insert each key in the ignition and turn to RUN for automatic programming.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive
Anti-Theft System (PATS) > Page 7960
Alarm Module: Service and Repair Module - Passive Anti-Theft Transceiver
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Twist the tilt wheel handle and shank and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the lower steering column shroud.
3 Remove the upper steering column shroud.
NOTE: The steering wheel has been removed for clarity.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive
Anti-Theft System (PATS) > Page 7961
5. Remove LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the insulator.
6. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
7. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
8. Remove the transceiver assembly.
1 Remove the screw.
2 Release the transceiver over the rib on the lock cylinder housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module - Passive
Anti-Theft System (PATS) > Page 7962
NOTE: Only apply pressure below the key cylinder rib.
3 Disconnect the electrical connector locator and electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
^ No key replacement or re-initialization needs to occur with the removal or installation of a new
PATS transceiver.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and
Operation
Multifunction Electronic Control Module: Description and Operation
The multifunction modules consist of the following:
^ Air Suspension Control Module
^ Driver Door Module (DDM)
^ Lighting Control Module (LCM)
The air suspension control module is linked to its own Data Link Connector (DLC). The air
suspension control module controls the air suspension and the Electronic Variable Orifice (EVO)
steering.
The Driver Door Module (DDM) is connected on the International Standards Organization (ISO)
9141 communication network. The DDM controls many functions including power windows, power
door locks and remote keyless entry.
The Lighting Control Module (LCM) is connected on the ISO 9141 communication network. The
LCM controls both interior and exterior lighting, back lighting, the battery saver and warning
chimes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Description and
Operation > Page 7966
Multifunction Electronic Control Module: Testing and Inspection
For Air Suspension concerns, See: Steering and Suspension/Suspension/Suspension Control (
Automatic - Electronic )
For Electronic Variable Orifice (EVO) Steering concerns,
For Warning Chime concerns, See: Instrument Panel, Gauges and Warning Indicators/Audible
Warning Device
For Lighting concerns, See: Lighting and Horns
For Power Window or Defroster concerns, See: Windows and Glass
For Power Door Lock concerns, See: Antitheft and Alarm Systems/Keyless Entry
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair
> Air Suspension Module
Multifunction Electronic Control Module: Service and Repair Air Suspension Module
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Lower the instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Lower the instrument panel lower insulator.
3. Remove the instrument panel lower insulator.
1 Disconnect the power point electrical connector.
2 Remove the footwell lamp.
3 Remove the instrument panel lower insulator.
4. Remove the air suspension module.
1 Disconnect the electrical connectors.
2 Remove the air suspension module.
^ Release the spring clips to remove the module from the bracket.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair
> Air Suspension Module > Page 7969
Multifunction Electronic Control Module: Service and Repair Driver Door Module
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair
> Air Suspension Module > Page 7970
Multifunction Electronic Control Module: Service and Repair Lighting Control Module
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the LH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Disconnect the courtesy lamp.
3 Remove the LH instrument panel insulator.
3. Position the LCM aside.
1 Remove the locking tab.
2 Release the locking tab.
3 Position the LCM aside.
4. Remove the LCM.
1 Disconnect the electrical connectors.
2 Remove the LCM.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair
> Air Suspension Module > Page 7971
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from New Generation STAR (NGS) Tester into the new module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Release the linkage.
3. Remove the rivets. 4. Remove the door handle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair
Front Door Latch: Service and Repair
REMOVAL
1. Remove the front door trim panel. 2. Remove the watershield.
3. Remove the screw.
4. Pivot the door latch release handle and remove from the rod.
5. Remove the clip.
6. Disconnect the door lock cylinder rod.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Page 7983
7. Disconnect the connectors.
8. Disconnect the connector.
9. Remove the rivet.
10. Remove the screws. 11. Remove the door lock actuator from the latch. 12. Remove the door
latch.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Page 7984
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip
Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip
Article No. 99-8-15
05/03/99
INTERIOR TRIM - DOOR TRIM PANEL
REPLACEMENT - SERVICE TIP
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2
LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR
LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999
F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER,
VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999
SUPER DUTY F SERIES
ISSUE There has been an increase in the number of door trim panel replacements due to damage.
This may be caused by a misconception of the type of fastener used to secure the door trim panel.
ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior
to removing the door trim panel. Use the Quick Reference Guide at the end of this article to
determine the type of fastener used for the vehicle being worked on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 7989
For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force
applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment
Scheme Chart to identify vehicles with molded hook designs.
WARNING
REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE
TRIM PANEL.
Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop
Manual, Section 01-05/501-05.
OTHER APPLICABLE ARTICLES: NONE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 7990
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Technical Service Bulletins > Page 7991
Front Door Panel: Service and Repair
Door Panel R&R;
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Technical Service Bulletins > Page 7992
Door Panel R&R;
Removal
1. Remove window regulator control switch housing by gently prying up, starting at the front.
2. Disconnect all connectors from window regulator control switch housing.
3. Remove inside door handle cup by gently prying at screwdriver slot with a screwdriver.
4. Remove screw directly beneath inside door handle.
5. Remove lower screw retaining front door trim panel to door inner panel.
6. Lift front door trim panel upward and snap out trim panel.
7. Disconnect wire harnesses from door panel as required and remove front door trim panel.
Installation
1. Connect wire harnesses to front door trim panel as required.
2. Install front door trim panel by pushing in and down until it snaps into place.
3. Install all self-tapping screws retaining front door trim panel to door inner panel.
4. Install inside door handle cup.
5. Install window regulator control switch housing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair
Front Door Window Glass: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Position the watershield out of the way.
1 Remove the speaker.
2 Disconnect the driver door module.
3 Position the watershield out of the way.
3. Remove the bolt. 4. Position the front door glass run front retainer forward.
5. Remove the rivets.
CAUTION: Do not attempt to forcibly remove the rivets as damage to the front door window glass
will result.
NOTE: Before removing rivets, it is necessary to place a suitable block support between the front door
window channel bracket and the door outer panel to help stabilize the front door window bracket
during rivet removal.
- Lower the front door window glass to gain access to the two front door window channel bracket
rivets.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair > Page 7996
6. Remove the front door window glass.
INSTALLATION
1. Position the front door window glass into the door frame. 2. Install two 1/4-inch rivets (use of
1/4-20 x 1 inch screw and washer assemblies and 1/4 inch-20 nut and washer are optional).
Tighten the nut (if
used) to 13 N.m (10 Lb-Ft).
NOTE: Align the front door window glass with the front door window channel bracket, if necessary.
3. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Position the watershield out of the way.
1 Remove the speaker.
2 Remove the driver door module.
3 Position the watershield out of the way.
3. Remove the front door window glass.
4. Disconnect the connector.
5. Remove the rivets.
6. Remove the Torx (R) screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8000
7. Remove the nuts. 8. Remove the regulator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair
REMOVAL
1. Remove the rear door trim panel.
2 Release the linkage.
3. Remove the rivets. 4. Remove the handle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair
Rear Door Latch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the watershield.
3. Remove the screw.
4. Pivot the door latch release handle and remove from the rod.
5. Remove the rivet.
6. Release the lock rod from the clip.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Page 8009
7. Remove the clip.
8. Disconnect the connectors.
9. Disconnect the connector.
10. Remove the rivet.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Page 8010
11. Remove the screws. 12. Remove the door latch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip
Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip
Article No. 99-8-15
05/03/99
INTERIOR TRIM - DOOR TRIM PANEL
REPLACEMENT - SERVICE TIP
FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA,
MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2
LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR
LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999
F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER,
VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999
SUPER DUTY F SERIES
ISSUE There has been an increase in the number of door trim panel replacements due to damage.
This may be caused by a misconception of the type of fastener used to secure the door trim panel.
ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior
to removing the door trim panel. Use the Quick Reference Guide at the end of this article to
determine the type of fastener used for the vehicle being worked on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8015
For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force
applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment
Scheme Chart to identify vehicles with molded hook designs.
WARNING
REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE
TRIM PANEL.
Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop
Manual, Section 01-05/501-05.
OTHER APPLICABLE ARTICLES: NONE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8016
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Technical Service Bulletins > Page 8017
Rear Door Panel: Service and Repair
Door Panel R&R;
Door Panel R&R;
Removal
1. Remove one screw from lower rear door panel.
2. Remove window regulator switch housing by gently prying up, starting at front.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Technical Service Bulletins > Page 8018
3. Disconnect all electrical connectors from window regulator control switch housing.
4. Remove inside door handle cup by gently prying at screwdriver slot.
5. Remove screw directly below release handle.
6. Lift rear door trim panel upward and snap out trim panel.
7. Disconnect any electrical switches if equipped, and remove rear door trim panel.
Installation
1. Follow Removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair
Rear Door Window Glass: Service and Repair
REMOVAL
1. Remove the rear door trim panel.
2. Remove the pull strap handle. 3. Remove the watershield.
4. Remove the bolt.
5. Remove the rivets.
CAUTION: Do not attempt to forcibly remove the rivets as damage to the rear door window glass
may result prior to removing the rivet center pins, it is necessary to place a suitable block support
between the door outer panel and the rear door window channel bracket to stabilize the rear door
window glass during rivet removal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Page 8022
6. Remove the bolt.
7. Remove the rear door window glass.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications
Rear Door Window Regulator: Specifications
Upper Regulator Mounting Nuts 12 Nm
Rear Door Window Regulator Motor Screws 6 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications > Page 8026
Rear Door Window Regulator: Service and Repair
REMOVAL
1. Remove the rear door trim panel.
2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the rear door window
glass.
5. Disconnect the connector.
6. Remove the rivets.
7. Remove the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications > Page 8027
8. Remove the rear door window regulator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Switch > Component
Information > Description and Operation
Fuel Door Lock Switch: Description and Operation
The fuel filler door lock switch:
- actuates a solenoid integral to the fuel filler door latch to release the fuel filler door.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement
Part
Article No. 01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES
1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION
LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD
MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree
Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical
switches will be available as a service replacement.
ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury
switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate
model year Workshop Manual as needed.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 201000, 201200
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available
Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages
Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8043
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8044
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8045
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8046
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8047
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking
Technical Service Bulletin # 99B09 Date: 990401
Campaign - Rear Frame Cosmetic Cracking
99B09
OWNER NOTIFICATION PROGRAM
Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV)
& Lincoln Town Car Limousine Prep Package & Livery Vehicles Registered in the State of NY Commercial Vehicle Frame Service
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8056
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8057
Attachment I - Administrative Information
OASIS OASIS will be activated for this program; however, only vehicles built on or before March
25, 1999 will be active in OASIS until a production action is incorporated. A supplement will be sent
(estimated July, 1999) to all dealers when the remaining vehicles have been added to OASIS.
If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state
and has the same package content and build dates as the "affected vehicles" described in this
bulletin, dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of
the concern, VIN, model year and mileage. If this information meets the requirements in this
bulletin and the customer is willing to provide needed information, approval to perform repairs and
submit a claim will be given by the Recall Hotline.
PLEASE NOTE
Correct all vehicles in stock before delivery.
CLAIMS Enter claims using DWE. See ACESII Manual.
OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures.
For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date
of the Owner Letter enter using DWE:
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8058
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing.
DEALER PRICE For latest prices, check or call your:
^ Order Processing Center
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
CLAIMS PREPARATION Enter using DWE. Use code information shown below:
^ Program Code: 99B09
^ Labor Operation: See above
See ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLE: 1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR
(LIMO, LIVERY)
SERVICE PROCEDURE
1. Record radio stations.
2. Disconnect battery negative cable.
3. Raise vehicle on hoist and remove rear wheels.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8059
4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128
Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure.
Refer to Figure 1.
5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8060
6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2.
7. If equipped with air spring, wrap air spring in welding blanket.
8. CAUTION:
If a crack is found, grind only enough metal away to form the V groove. Do not grind completely
through frame parent metal. If frame is cracked, grind a V groove in crack, then remove E coat from
around crack. Mig weld the groove using standard mig welding procedures. See Figure 2 for
location of mig welder grounding clamp.
9. CAUTION:
Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind
frame parent metal. Prep the frame by removing any paint in the affected area. Grind only the
welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not
"rock"). After grinding, position the plate to check that it sits flush and if necessary, strike any weld
with a punch and hammer to deflect the metal enough to allow proper fit.
10.
NOTE:
Reinforcement plate is properly positioned when the entire access hole is covered and the rear
edge is no more than 10 mm (approximately 3/8 in.) from the "lance" on the frame. If necessary,
verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and
clamp reinforcement plate onto frame completely covering access hole.
11. CAUTION:
Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard
mig welding procedures, tack weld reinforcement plate to frame on the two (2) outboard corners,
then proceed to weld the perimeter of the reinforcement plate in sequence shown in Figure 2.
12. Remove weld blankets, if previously installed.
13. Spray undercoating on plate and welds being careful to avoid any overspray.
14. Reclip ABS sensor wire.
15. Repeat steps 6 through 14 for other side.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8061
16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist.
17. Connect battery negative cable.
18. Program radio stations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: >
99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8062
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking
Technical Service Bulletin # 04-4-1 Date: 040308
Frame - Rear Frame Side Member Cracking
Article No. 04-4-1
03/08/04
^ CHASSIS - FRAME CRACKING - SERVICE PROCEDURE
^ SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE
FORD: 1998-2002 CROWN VICTORIA
ISSUE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8068
Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may
exhibit cracks in the rear of the frame side member between the upper and lower trailing arm
brackets, or around the opening to the lower trailing arm bracket access hole for the flag nut in the
bottom of the frame. These cracks may result from driving events that place extreme stress on the
frame (i.e. rear vehicle impact, driving over curbs, high speed through driveway transitions,
becoming airborne etc...). Refer to Figures 1, 2 and 3 for examples of cracks.
ACTION
To service, perform the following procedures to repair the cracks and reinforce the frame.
NOTE
READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY
REPAIR.
NOTE
INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD
HINDER THIS SERVICE PROCEDURE.
NOTE
ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON
BOTH SIDES OF THE VEHICLE'S FRAME, THEN TWO (2) KITS WILL BE REQUIRED.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8069
NOTE
EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT
AND ONE (1) FOR THE 'RIGHT HAND SIDE OF THE FRAME. AT THE END OF THE REPAIR,
ONE (1) OF THE REINFORCEMENTS FROM EACH KIT WILL BE LEFT OVER. (EXAMPLE: IF A
KIT IS USED TO FIX THE RIGHT HAND SIDE OF THE FRAME, THERE WILL BE A LEFT HAND
REINFORCEMENT BRACKET LEFT OVER AFTER THE REPAIRS ARE COMPLETED, AND
VICE VERSA).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040401A Repair Cracks In One 4.2 Hrs.
Frame Rail Then Install Reinforcement Plates And Structural Foam
040401B Repair Cracks In Both 4.5 Hrs.
Frame Rails Then Install Reinforcement Plates And Structural Foam
DEALER CODING
CONDITION
BASIC PART NO. CODE
5B118 01
Disclaimer
Service Procedure
NOTE
PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND
REINFORCE ONE OR BOTH SIDES OF THE FRAME. IT SHOULD BE NOTED THAT IF THE
VEHICLE IS SUBJECTED TO A HIGH STRESS EVENT AGAIN, NEW CRACKS MIGHT APPEAR
IN THAT AREA.
CAUTION
ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL
SECTION 414-01 BEFORE USING ANY ELECTRICAL WELDING EQUIPMENT. USE ONLY MIG
ER-70-56 WIRE WHEN WELDING.
REAR FRAME AND BODY SPLIT
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF
THE FRAME.
In this procedure the bumper cover will be loosened to prevent damage to the cover when the body
of the vehicle is lifted away from the vehicle frame. The frame will be split from the body to provide
clearance necessary to repair cracks on the top of the vehicle frame.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8070
1. Position the vehicle on a hoist making sure there is adequate access to the body mount bolts
(Figure 4) and the lower trailing arm flag nut access hole (see Workshop Manual Section 100-02).
2. Open the hood and disconnect the battery per Workshop Manual Section 414-01.
3. Open the trunk.
4. Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts
in the trunk (two (2) on each side) (Figure 5 shows left hand side).
NOTE
IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL.
5. Raise the vehicle to chest height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8071
6. Remove the rear wheels.
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Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8072
7. Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3)
screws), (Figure 6) and the push pin type retainers from bottom sides of bumper cover (two (2) or
three (3) on each side) (Figure 7), six (6) push pin-type retainers (three (3) on each side) in the
wheel well at the leading edge of the bumper (Figure 8).
8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations
of body mount bolts.
NOTE
THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT.
9. Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body
drain plugs, partially under the trunk and the fuel tank (Figure 9).
10. It present, unclip the ground strap from the # 6 body holes on the frame on the right and left
hand sides. The ground straps are located between the # 6 body hole and the rear cross member.
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Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8073
NOTE
DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP
ON THE BUMPER REINFORCEMENT BAR. IF IT HANGS UP, THE BUMPER COVER MAY BE
DAMAGED.
11. With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower
the lift so that the body splits from the frame. It will be necessary to create about a 12.7 cm (5") air
gap between the frame and the body, at the # 5 body mounts location. Insert a 11.5 to 12.7 mm
(4.5" to 5") tall block of 4X4 wood between the frame and the body mounts at the # 5 body mount
location on both sides of the vehicle. The block will be flush to the cage nut reinforcement (Figure
10).
12. Raise the hoist and remove the jackscrews.
REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM
MOUNTING BRACKETS
NOTE
REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT
PERFORM THIS PROCEDURE IF CRACKS ARE NOT PRESENT ON THE SIDE RAIL
BETWEEN THE UPPER AND LOWER TRAILING ARM BRACKETS.
NOTE
PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8074
1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for
improved access~to the frame crack (Figure 11).
2. On the left side only, remove the brake line clip and reposition the line away from welding area.
3. Use an angle grinder to clean off paint and dress the weld area.
4. Weld crack as necessary.
5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas.
6. Replace the brake line.
7. Re-bend weld flange into place.
LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR
REINFORCEMENT
In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole
opening will be repaired. A metal blocker baffle (4W73-4A145-AA) will be inserted into the side rail,
and a reinforcement plate (4W73-5A123-AA or 4W73-5A124-M) will be welded to the bottom rail of
the frame to close the access hole to strengthen that section hole.
NOTE
THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH
WILL BE INTRODUCED INTO THE FRAME.
1. Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole
is located on the bottom of the frame, directly under the lower trailing arm mounting bracket.
Inspect for cracks at the lower trailing arm access hole (Figure 3). If cracks are present repair them
as necessary.
2. Use an angle grinder to clean off paint and dress the weld area.
3. Weld crack as necessary.
4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on
the middle of the part.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8075
5. Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the
flanges. The blocker baffle will prevent the structural foam from running out of the frame and/or
covering the trailing arm nut. The flanges should face the front of the car (Figure 12).
6. Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the
frame rail section. Perform one of the following procedures:
a. On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear
edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the
top rear weld on the lower trailing arm bracket. Inspect the blocker baffle for a good seal between
the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the
blocker baffle to improve seal between the blocker baffle and the frame. The flag nut may need to
be bent out of the way to accommodate the blocker baffle. Tack weld the blocker baffle.
b. On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of
the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear
weld on the lower trailing arm bracket (Figure 12). Inspect the blocker baffle for a good seal
between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of
the blocker baffle to improve seal between the blocker baffle and the frame. Tack weld the blocker
baffle.
7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including
any welds that may have been added to repair
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8076
cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13).
Do not grind away the parent metal. The reinforcement plate must be located flush to the frame.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8077
8. Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or
4W73-5A124-M left hand side (marked "L") to the center of the trailing arm bolt taking care that the
frame rail does not overlap the slot (Figure 14). Tack in place, then weld around the reinforcement
plate completely (Figure 15 and 16).
REINFORCE FRAME WITH STRUCTURAL FOAM
In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will
add strength to the frame and reduce the potential for cracks in the frame in the area.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8078
1. Clean around the tooling hole and all other holes in the area on the frame rail located between
the upper and lower trailing arm-mounting brackets (Figure 17 and 18).
2. Apply duct tape over the holes.
3. Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy
introduction of the nozzle into the tooling hole through the tape (Figure 19).
4. Lower the vehicle to chest height.
NOTE
IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF
MOTORCRAFT STRUCTURAL FOAM AS OUTLINED IN STEPS 5 THROUGH 7.
ADDITIONALLY, THE STRUCTURAL FOAM WILL CAUSE THE SIDE MEMBER SURFACE TO
BECOME VERY WARM AS A RESULT OF THE CHEMICAL REACTION.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8079
5. Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the
tubes front and back with a heat gun to approximately 71.1 °C (160 °F). This will help soften the
two parts of the Structural Foam so that it will flow out of the tubes and through the mixing wand
easily (Figure 20).
6. Remove the small black plugs from a tube of structural foam. Install the nozzle
(4W73-19H255-M) and replace the holding nuts. Balance the plungers by gunning out some
material. Ensure that it comes out from both tubes. Press the tab on the back of the gun to relieve
pressure. This will prevent the foam from streaming out of the tube uncontrollably.
7. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19).
Pump the tube of Structural Foam into the frame rail. When the Structural Foam rises to the height
of the tooling hole, it will be necessary to duct tape the hole when switching tubes to prevent
leakage of the Structural Foam.
NOTE
REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT
STRUCTURAL FOAM HAVE BEEN PUMPED INTO THE FRAME. ALLOW AT LEAST THIRTY
(30) MINUTES FOR THE STRUCTURAL FOAM TO CURE BEFORE REMOVING THE DUCT
TAPE.
8. Raise the vehicle all the way up.
9. Remove duct tape.
10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas.
REASSEMBLE FRAME AND BODY
In the following steps the frame will be reassembled to the body, and the bumper fascia will be
reinstalled.
NOTE
REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS
PERFORMED.
1. Partially raise the vehicle.
2. Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the
body drain plugs, partially under the trunk and the fuel tank (Figure 9).
3. Lower the hoist until the 2X6 block fits snug against the body.
4. Remove the wood block between the frame and the body mounts at the # 5 body mount location
on each side of the vehicle (Figure 10). It may be necessary to further lower the hoist by 6 to 12
mm (1/4" to 1/2").
5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch
the bumper cover to make sure that it does not
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer
Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8080
become damaged.
6. Remove the jackscrews and the 2X6 block from under the vehicle.
7. Clip the ground strap to the #6 body holes on the frame on the right and left hand.
8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides.
9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft).
10. Partially lower the vehicle to waist height.
11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side).
12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side).
13. Reposition trunk trim sides.
14. Partially raise the vehicle.
15. Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of
the bumper (Figure 8) and the push pin-type retainers (two (2) or three (3) on each side) from
bottom sides of bumper cover (Figure 7).
16. Partially lower the vehicle.
17. Replace the rear wheel and tire assemblies.
18. Lower the hoist.
19. Close the trunk.
20. Reconnect the battery per Workshop Manual: Section 414-01.
21. Close the hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking
Technical Service Bulletin # 04-4-1 Date: 040308
Frame - Rear Frame Side Member Cracking
Article No. 04-4-1
03/08/04
^ CHASSIS - FRAME CRACKING - SERVICE PROCEDURE
^ SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE
FORD: 1998-2002 CROWN VICTORIA
ISSUE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8086
Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may
exhibit cracks in the rear of the frame side member between the upper and lower trailing arm
brackets, or around the opening to the lower trailing arm bracket access hole for the flag nut in the
bottom of the frame. These cracks may result from driving events that place extreme stress on the
frame (i.e. rear vehicle impact, driving over curbs, high speed through driveway transitions,
becoming airborne etc...). Refer to Figures 1, 2 and 3 for examples of cracks.
ACTION
To service, perform the following procedures to repair the cracks and reinforce the frame.
NOTE
READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY
REPAIR.
NOTE
INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD
HINDER THIS SERVICE PROCEDURE.
NOTE
ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON
BOTH SIDES OF THE VEHICLE'S FRAME, THEN TWO (2) KITS WILL BE REQUIRED.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8087
NOTE
EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT
AND ONE (1) FOR THE 'RIGHT HAND SIDE OF THE FRAME. AT THE END OF THE REPAIR,
ONE (1) OF THE REINFORCEMENTS FROM EACH KIT WILL BE LEFT OVER. (EXAMPLE: IF A
KIT IS USED TO FIX THE RIGHT HAND SIDE OF THE FRAME, THERE WILL BE A LEFT HAND
REINFORCEMENT BRACKET LEFT OVER AFTER THE REPAIRS ARE COMPLETED, AND
VICE VERSA).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040401A Repair Cracks In One 4.2 Hrs.
Frame Rail Then Install Reinforcement Plates And Structural Foam
040401B Repair Cracks In Both 4.5 Hrs.
Frame Rails Then Install Reinforcement Plates And Structural Foam
DEALER CODING
CONDITION
BASIC PART NO. CODE
5B118 01
Disclaimer
Service Procedure
NOTE
PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND
REINFORCE ONE OR BOTH SIDES OF THE FRAME. IT SHOULD BE NOTED THAT IF THE
VEHICLE IS SUBJECTED TO A HIGH STRESS EVENT AGAIN, NEW CRACKS MIGHT APPEAR
IN THAT AREA.
CAUTION
ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL
SECTION 414-01 BEFORE USING ANY ELECTRICAL WELDING EQUIPMENT. USE ONLY MIG
ER-70-56 WIRE WHEN WELDING.
REAR FRAME AND BODY SPLIT
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF
THE FRAME.
In this procedure the bumper cover will be loosened to prevent damage to the cover when the body
of the vehicle is lifted away from the vehicle frame. The frame will be split from the body to provide
clearance necessary to repair cracks on the top of the vehicle frame.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8088
1. Position the vehicle on a hoist making sure there is adequate access to the body mount bolts
(Figure 4) and the lower trailing arm flag nut access hole (see Workshop Manual Section 100-02).
2. Open the hood and disconnect the battery per Workshop Manual Section 414-01.
3. Open the trunk.
4. Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts
in the trunk (two (2) on each side) (Figure 5 shows left hand side).
NOTE
IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL.
5. Raise the vehicle to chest height.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8089
6. Remove the rear wheels.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8090
7. Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3)
screws), (Figure 6) and the push pin type retainers from bottom sides of bumper cover (two (2) or
three (3) on each side) (Figure 7), six (6) push pin-type retainers (three (3) on each side) in the
wheel well at the leading edge of the bumper (Figure 8).
8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations
of body mount bolts.
NOTE
THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT.
9. Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body
drain plugs, partially under the trunk and the fuel tank (Figure 9).
10. It present, unclip the ground strap from the # 6 body holes on the frame on the right and left
hand sides. The ground straps are located between the # 6 body hole and the rear cross member.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8091
NOTE
DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP
ON THE BUMPER REINFORCEMENT BAR. IF IT HANGS UP, THE BUMPER COVER MAY BE
DAMAGED.
11. With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower
the lift so that the body splits from the frame. It will be necessary to create about a 12.7 cm (5") air
gap between the frame and the body, at the # 5 body mounts location. Insert a 11.5 to 12.7 mm
(4.5" to 5") tall block of 4X4 wood between the frame and the body mounts at the # 5 body mount
location on both sides of the vehicle. The block will be flush to the cage nut reinforcement (Figure
10).
12. Raise the hoist and remove the jackscrews.
REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM
MOUNTING BRACKETS
NOTE
REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT
PERFORM THIS PROCEDURE IF CRACKS ARE NOT PRESENT ON THE SIDE RAIL
BETWEEN THE UPPER AND LOWER TRAILING ARM BRACKETS.
NOTE
PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8092
1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for
improved access~to the frame crack (Figure 11).
2. On the left side only, remove the brake line clip and reposition the line away from welding area.
3. Use an angle grinder to clean off paint and dress the weld area.
4. Weld crack as necessary.
5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas.
6. Replace the brake line.
7. Re-bend weld flange into place.
LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR
REINFORCEMENT
In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole
opening will be repaired. A metal blocker baffle (4W73-4A145-AA) will be inserted into the side rail,
and a reinforcement plate (4W73-5A123-AA or 4W73-5A124-M) will be welded to the bottom rail of
the frame to close the access hole to strengthen that section hole.
NOTE
THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH
WILL BE INTRODUCED INTO THE FRAME.
1. Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole
is located on the bottom of the frame, directly under the lower trailing arm mounting bracket.
Inspect for cracks at the lower trailing arm access hole (Figure 3). If cracks are present repair them
as necessary.
2. Use an angle grinder to clean off paint and dress the weld area.
3. Weld crack as necessary.
4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on
the middle of the part.
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Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8093
5. Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the
flanges. The blocker baffle will prevent the structural foam from running out of the frame and/or
covering the trailing arm nut. The flanges should face the front of the car (Figure 12).
6. Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the
frame rail section. Perform one of the following procedures:
a. On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear
edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the
top rear weld on the lower trailing arm bracket. Inspect the blocker baffle for a good seal between
the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the
blocker baffle to improve seal between the blocker baffle and the frame. The flag nut may need to
be bent out of the way to accommodate the blocker baffle. Tack weld the blocker baffle.
b. On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of
the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear
weld on the lower trailing arm bracket (Figure 12). Inspect the blocker baffle for a good seal
between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of
the blocker baffle to improve seal between the blocker baffle and the frame. Tack weld the blocker
baffle.
7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including
any welds that may have been added to repair
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cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13).
Do not grind away the parent metal. The reinforcement plate must be located flush to the frame.
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8. Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or
4W73-5A124-M left hand side (marked "L") to the center of the trailing arm bolt taking care that the
frame rail does not overlap the slot (Figure 14). Tack in place, then weld around the reinforcement
plate completely (Figure 15 and 16).
REINFORCE FRAME WITH STRUCTURAL FOAM
In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will
add strength to the frame and reduce the potential for cracks in the frame in the area.
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1. Clean around the tooling hole and all other holes in the area on the frame rail located between
the upper and lower trailing arm-mounting brackets (Figure 17 and 18).
2. Apply duct tape over the holes.
3. Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy
introduction of the nozzle into the tooling hole through the tape (Figure 19).
4. Lower the vehicle to chest height.
NOTE
IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF
MOTORCRAFT STRUCTURAL FOAM AS OUTLINED IN STEPS 5 THROUGH 7.
ADDITIONALLY, THE STRUCTURAL FOAM WILL CAUSE THE SIDE MEMBER SURFACE TO
BECOME VERY WARM AS A RESULT OF THE CHEMICAL REACTION.
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5. Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the
tubes front and back with a heat gun to approximately 71.1 °C (160 °F). This will help soften the
two parts of the Structural Foam so that it will flow out of the tubes and through the mixing wand
easily (Figure 20).
6. Remove the small black plugs from a tube of structural foam. Install the nozzle
(4W73-19H255-M) and replace the holding nuts. Balance the plungers by gunning out some
material. Ensure that it comes out from both tubes. Press the tab on the back of the gun to relieve
pressure. This will prevent the foam from streaming out of the tube uncontrollably.
7. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19).
Pump the tube of Structural Foam into the frame rail. When the Structural Foam rises to the height
of the tooling hole, it will be necessary to duct tape the hole when switching tubes to prevent
leakage of the Structural Foam.
NOTE
REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT
STRUCTURAL FOAM HAVE BEEN PUMPED INTO THE FRAME. ALLOW AT LEAST THIRTY
(30) MINUTES FOR THE STRUCTURAL FOAM TO CURE BEFORE REMOVING THE DUCT
TAPE.
8. Raise the vehicle all the way up.
9. Remove duct tape.
10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas.
REASSEMBLE FRAME AND BODY
In the following steps the frame will be reassembled to the body, and the bumper fascia will be
reinstalled.
NOTE
REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS
PERFORMED.
1. Partially raise the vehicle.
2. Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the
body drain plugs, partially under the trunk and the fuel tank (Figure 9).
3. Lower the hoist until the 2X6 block fits snug against the body.
4. Remove the wood block between the frame and the body mounts at the # 5 body mount location
on each side of the vehicle (Figure 10). It may be necessary to further lower the hoist by 6 to 12
mm (1/4" to 1/2").
5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch
the bumper cover to make sure that it does not
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become damaged.
6. Remove the jackscrews and the 2X6 block from under the vehicle.
7. Clip the ground strap to the #6 body holes on the frame on the right and left hand.
8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides.
9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft).
10. Partially lower the vehicle to waist height.
11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side).
12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side).
13. Reposition trunk trim sides.
14. Partially raise the vehicle.
15. Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of
the bumper (Figure 8) and the push pin-type retainers (two (2) or three (3) on each side) from
bottom sides of bumper cover (Figure 7).
16. Partially lower the vehicle.
17. Replace the rear wheel and tire assemblies.
18. Lower the hoist.
19. Close the trunk.
20. Reconnect the battery per Workshop Manual: Section 414-01.
21. Close the hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking
Technical Service Bulletin # 99B09 Date: 990401
Campaign - Rear Frame Cosmetic Cracking
99B09
OWNER NOTIFICATION PROGRAM
Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV)
& Lincoln Town Car Limousine Prep Package & Livery Vehicles Registered in the State of NY Commercial Vehicle Frame Service
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Customer Notification Letter
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Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All
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Attachment I - Administrative Information
OASIS OASIS will be activated for this program; however, only vehicles built on or before March
25, 1999 will be active in OASIS until a production action is incorporated. A supplement will be sent
(estimated July, 1999) to all dealers when the remaining vehicles have been added to OASIS.
If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state
and has the same package content and build dates as the "affected vehicles" described in this
bulletin, dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of
the concern, VIN, model year and mileage. If this information meets the requirements in this
bulletin and the customer is willing to provide needed information, approval to perform repairs and
submit a claim will be given by the Recall Hotline.
PLEASE NOTE
Correct all vehicles in stock before delivery.
CLAIMS Enter claims using DWE. See ACESII Manual.
OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures.
For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date
of the Owner Letter enter using DWE:
Attachment II - Labor and Parts Information
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LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing.
DEALER PRICE For latest prices, check or call your:
^ Order Processing Center
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
CLAIMS PREPARATION Enter using DWE. Use code information shown below:
^ Program Code: 99B09
^ Labor Operation: See above
See ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLE: 1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR
(LIMO, LIVERY)
SERVICE PROCEDURE
1. Record radio stations.
2. Disconnect battery negative cable.
3. Raise vehicle on hoist and remove rear wheels.
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4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128
Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure.
Refer to Figure 1.
5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1.
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6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2.
7. If equipped with air spring, wrap air spring in welding blanket.
8. CAUTION:
If a crack is found, grind only enough metal away to form the V groove. Do not grind completely
through frame parent metal. If frame is cracked, grind a V groove in crack, then remove E coat from
around crack. Mig weld the groove using standard mig welding procedures. See Figure 2 for
location of mig welder grounding clamp.
9. CAUTION:
Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind
frame parent metal. Prep the frame by removing any paint in the affected area. Grind only the
welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not
"rock"). After grinding, position the plate to check that it sits flush and if necessary, strike any weld
with a punch and hammer to deflect the metal enough to allow proper fit.
10.
NOTE:
Reinforcement plate is properly positioned when the entire access hole is covered and the rear
edge is no more than 10 mm (approximately 3/8 in.) from the "lance" on the frame. If necessary,
verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and
clamp reinforcement plate onto frame completely covering access hole.
11. CAUTION:
Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard
mig welding procedures, tack weld reinforcement plate to frame on the two (2) outboard corners,
then proceed to weld the perimeter of the reinforcement plate in sequence shown in Figure 2.
12. Remove weld blankets, if previously installed.
13. Spray undercoating on plate and welds being careful to avoid any overspray.
14. Reclip ABS sensor wire.
15. Repeat steps 6 through 14 for other side.
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16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist.
17. Connect battery negative cable.
18. Program radio stations.
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Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking
Technical Service Bulletin # 04-4-1 Date: 040308
Frame - Rear Frame Side Member Cracking
Article No. 04-4-1
03/08/04
^ CHASSIS - FRAME CRACKING - SERVICE PROCEDURE
^ SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE
FORD: 1998-2002 CROWN VICTORIA
ISSUE
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Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may
exhibit cracks in the rear of the frame side member between the upper and lower trailing arm
brackets, or around the opening to the lower trailing arm bracket access hole for the flag nut in the
bottom of the frame. These cracks may result from driving events that place extreme stress on the
frame (i.e. rear vehicle impact, driving over curbs, high speed through driveway transitions,
becoming airborne etc...). Refer to Figures 1, 2 and 3 for examples of cracks.
ACTION
To service, perform the following procedures to repair the cracks and reinforce the frame.
NOTE
READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY
REPAIR.
NOTE
INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD
HINDER THIS SERVICE PROCEDURE.
NOTE
ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON
BOTH SIDES OF THE VEHICLE'S FRAME, THEN TWO (2) KITS WILL BE REQUIRED.
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NOTE
EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT
AND ONE (1) FOR THE 'RIGHT HAND SIDE OF THE FRAME. AT THE END OF THE REPAIR,
ONE (1) OF THE REINFORCEMENTS FROM EACH KIT WILL BE LEFT OVER. (EXAMPLE: IF A
KIT IS USED TO FIX THE RIGHT HAND SIDE OF THE FRAME, THERE WILL BE A LEFT HAND
REINFORCEMENT BRACKET LEFT OVER AFTER THE REPAIRS ARE COMPLETED, AND
VICE VERSA).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040401A Repair Cracks In One 4.2 Hrs.
Frame Rail Then Install Reinforcement Plates And Structural Foam
040401B Repair Cracks In Both 4.5 Hrs.
Frame Rails Then Install Reinforcement Plates And Structural Foam
DEALER CODING
CONDITION
BASIC PART NO. CODE
5B118 01
Disclaimer
Service Procedure
NOTE
PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND
REINFORCE ONE OR BOTH SIDES OF THE FRAME. IT SHOULD BE NOTED THAT IF THE
VEHICLE IS SUBJECTED TO A HIGH STRESS EVENT AGAIN, NEW CRACKS MIGHT APPEAR
IN THAT AREA.
CAUTION
ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL
SECTION 414-01 BEFORE USING ANY ELECTRICAL WELDING EQUIPMENT. USE ONLY MIG
ER-70-56 WIRE WHEN WELDING.
REAR FRAME AND BODY SPLIT
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF
THE FRAME.
In this procedure the bumper cover will be loosened to prevent damage to the cover when the body
of the vehicle is lifted away from the vehicle frame. The frame will be split from the body to provide
clearance necessary to repair cracks on the top of the vehicle frame.
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1. Position the vehicle on a hoist making sure there is adequate access to the body mount bolts
(Figure 4) and the lower trailing arm flag nut access hole (see Workshop Manual Section 100-02).
2. Open the hood and disconnect the battery per Workshop Manual Section 414-01.
3. Open the trunk.
4. Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts
in the trunk (two (2) on each side) (Figure 5 shows left hand side).
NOTE
IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL.
5. Raise the vehicle to chest height.
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6. Remove the rear wheels.
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7. Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3)
screws), (Figure 6) and the push pin type retainers from bottom sides of bumper cover (two (2) or
three (3) on each side) (Figure 7), six (6) push pin-type retainers (three (3) on each side) in the
wheel well at the leading edge of the bumper (Figure 8).
8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations
of body mount bolts.
NOTE
THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT.
9. Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body
drain plugs, partially under the trunk and the fuel tank (Figure 9).
10. It present, unclip the ground strap from the # 6 body holes on the frame on the right and left
hand sides. The ground straps are located between the # 6 body hole and the rear cross member.
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NOTE
DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP
ON THE BUMPER REINFORCEMENT BAR. IF IT HANGS UP, THE BUMPER COVER MAY BE
DAMAGED.
11. With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower
the lift so that the body splits from the frame. It will be necessary to create about a 12.7 cm (5") air
gap between the frame and the body, at the # 5 body mounts location. Insert a 11.5 to 12.7 mm
(4.5" to 5") tall block of 4X4 wood between the frame and the body mounts at the # 5 body mount
location on both sides of the vehicle. The block will be flush to the cage nut reinforcement (Figure
10).
12. Raise the hoist and remove the jackscrews.
REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM
MOUNTING BRACKETS
NOTE
REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT
PERFORM THIS PROCEDURE IF CRACKS ARE NOT PRESENT ON THE SIDE RAIL
BETWEEN THE UPPER AND LOWER TRAILING ARM BRACKETS.
NOTE
PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY.
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1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for
improved access~to the frame crack (Figure 11).
2. On the left side only, remove the brake line clip and reposition the line away from welding area.
3. Use an angle grinder to clean off paint and dress the weld area.
4. Weld crack as necessary.
5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas.
6. Replace the brake line.
7. Re-bend weld flange into place.
LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR
REINFORCEMENT
In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole
opening will be repaired. A metal blocker baffle (4W73-4A145-AA) will be inserted into the side rail,
and a reinforcement plate (4W73-5A123-AA or 4W73-5A124-M) will be welded to the bottom rail of
the frame to close the access hole to strengthen that section hole.
NOTE
THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH
WILL BE INTRODUCED INTO THE FRAME.
1. Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole
is located on the bottom of the frame, directly under the lower trailing arm mounting bracket.
Inspect for cracks at the lower trailing arm access hole (Figure 3). If cracks are present repair them
as necessary.
2. Use an angle grinder to clean off paint and dress the weld area.
3. Weld crack as necessary.
4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on
the middle of the part.
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5. Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the
flanges. The blocker baffle will prevent the structural foam from running out of the frame and/or
covering the trailing arm nut. The flanges should face the front of the car (Figure 12).
6. Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the
frame rail section. Perform one of the following procedures:
a. On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear
edge of the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the
top rear weld on the lower trailing arm bracket. Inspect the blocker baffle for a good seal between
the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of the
blocker baffle to improve seal between the blocker baffle and the frame. The flag nut may need to
be bent out of the way to accommodate the blocker baffle. Tack weld the blocker baffle.
b. On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of
the access hole. The top end of the baffle must be 6 to 12 mm (1/4" to 1/2") forward of the top rear
weld on the lower trailing arm bracket (Figure 12). Inspect the blocker baffle for a good seal
between the frame and the blocker baffle. If needed, using a flat screwdriver push all the flanges of
the blocker baffle to improve seal between the blocker baffle and the frame. Tack weld the blocker
baffle.
7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including
any welds that may have been added to repair
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cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13).
Do not grind away the parent metal. The reinforcement plate must be located flush to the frame.
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8. Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or
4W73-5A124-M left hand side (marked "L") to the center of the trailing arm bolt taking care that the
frame rail does not overlap the slot (Figure 14). Tack in place, then weld around the reinforcement
plate completely (Figure 15 and 16).
REINFORCE FRAME WITH STRUCTURAL FOAM
In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will
add strength to the frame and reduce the potential for cracks in the frame in the area.
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1. Clean around the tooling hole and all other holes in the area on the frame rail located between
the upper and lower trailing arm-mounting brackets (Figure 17 and 18).
2. Apply duct tape over the holes.
3. Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy
introduction of the nozzle into the tooling hole through the tape (Figure 19).
4. Lower the vehicle to chest height.
NOTE
IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF
MOTORCRAFT STRUCTURAL FOAM AS OUTLINED IN STEPS 5 THROUGH 7.
ADDITIONALLY, THE STRUCTURAL FOAM WILL CAUSE THE SIDE MEMBER SURFACE TO
BECOME VERY WARM AS A RESULT OF THE CHEMICAL REACTION.
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5. Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the
tubes front and back with a heat gun to approximately 71.1 °C (160 °F). This will help soften the
two parts of the Structural Foam so that it will flow out of the tubes and through the mixing wand
easily (Figure 20).
6. Remove the small black plugs from a tube of structural foam. Install the nozzle
(4W73-19H255-M) and replace the holding nuts. Balance the plungers by gunning out some
material. Ensure that it comes out from both tubes. Press the tab on the back of the gun to relieve
pressure. This will prevent the foam from streaming out of the tube uncontrollably.
7. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19).
Pump the tube of Structural Foam into the frame rail. When the Structural Foam rises to the height
of the tooling hole, it will be necessary to duct tape the hole when switching tubes to prevent
leakage of the Structural Foam.
NOTE
REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT
STRUCTURAL FOAM HAVE BEEN PUMPED INTO THE FRAME. ALLOW AT LEAST THIRTY
(30) MINUTES FOR THE STRUCTURAL FOAM TO CURE BEFORE REMOVING THE DUCT
TAPE.
8. Raise the vehicle all the way up.
9. Remove duct tape.
10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas.
REASSEMBLE FRAME AND BODY
In the following steps the frame will be reassembled to the body, and the bumper fascia will be
reinstalled.
NOTE
REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS
PERFORMED.
1. Partially raise the vehicle.
2. Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the
body drain plugs, partially under the trunk and the fuel tank (Figure 9).
3. Lower the hoist until the 2X6 block fits snug against the body.
4. Remove the wood block between the frame and the body mounts at the # 5 body mount location
on each side of the vehicle (Figure 10). It may be necessary to further lower the hoist by 6 to 12
mm (1/4" to 1/2").
5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch
the bumper cover to make sure that it does not
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking > Page 8127
become damaged.
6. Remove the jackscrews and the 2X6 block from under the vehicle.
7. Clip the ground strap to the #6 body holes on the frame on the right and left hand.
8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides.
9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft).
10. Partially lower the vehicle to waist height.
11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side).
12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side).
13. Reposition trunk trim sides.
14. Partially raise the vehicle.
15. Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of
the bumper (Figure 8) and the push pin-type retainers (two (2) or three (3) on each side) from
bottom sides of bumper cover (Figure 7).
16. Partially lower the vehicle.
17. Replace the rear wheel and tire assemblies.
18. Lower the hoist.
19. Close the trunk.
20. Reconnect the battery per Workshop Manual: Section 414-01.
21. Close the hood.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking
Technical Service Bulletin # 99B09 Date: 990401
Campaign - Rear Frame Cosmetic Cracking
99B09
OWNER NOTIFICATION PROGRAM
Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV)
& Lincoln Town Car Limousine Prep Package & Livery Vehicles Registered in the State of NY Commercial Vehicle Frame Service
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Customer Notification Letter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8133
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8134
Attachment I - Administrative Information
OASIS OASIS will be activated for this program; however, only vehicles built on or before March
25, 1999 will be active in OASIS until a production action is incorporated. A supplement will be sent
(estimated July, 1999) to all dealers when the remaining vehicles have been added to OASIS.
If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state
and has the same package content and build dates as the "affected vehicles" described in this
bulletin, dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of
the concern, VIN, model year and mileage. If this information meets the requirements in this
bulletin and the customer is willing to provide needed information, approval to perform repairs and
submit a claim will be given by the Recall Hotline.
PLEASE NOTE
Correct all vehicles in stock before delivery.
CLAIMS Enter claims using DWE. See ACESII Manual.
OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures.
For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date
of the Owner Letter enter using DWE:
Attachment II - Labor and Parts Information
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8135
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts
requirement through normal order processing.
DEALER PRICE For latest prices, check or call your:
^ Order Processing Center
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford
Customer Service Division in accordance with Policy Procedure Bulletin 4000.
CLAIMS PREPARATION Enter using DWE. Use code information shown below:
^ Program Code: 99B09
^ Labor Operation: See above
See ACESII manual for detailed instructions.
Attachment III - Technical Information
AFFECTED VEHICLE: 1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR
(LIMO, LIVERY)
SERVICE PROCEDURE
1. Record radio stations.
2. Disconnect battery negative cable.
3. Raise vehicle on hoist and remove rear wheels.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8136
4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128
Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure.
Refer to Figure 1.
5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8137
6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2.
7. If equipped with air spring, wrap air spring in welding blanket.
8. CAUTION:
If a crack is found, grind only enough metal away to form the V groove. Do not grind completely
through frame parent metal. If frame is cracked, grind a V groove in crack, then remove E coat from
around crack. Mig weld the groove using standard mig welding procedures. See Figure 2 for
location of mig welder grounding clamp.
9. CAUTION:
Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind
frame parent metal. Prep the frame by removing any paint in the affected area. Grind only the
welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not
"rock"). After grinding, position the plate to check that it sits flush and if necessary, strike any weld
with a punch and hammer to deflect the metal enough to allow proper fit.
10.
NOTE:
Reinforcement plate is properly positioned when the entire access hole is covered and the rear
edge is no more than 10 mm (approximately 3/8 in.) from the "lance" on the frame. If necessary,
verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and
clamp reinforcement plate onto frame completely covering access hole.
11. CAUTION:
Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard
mig welding procedures, tack weld reinforcement plate to frame on the two (2) outboard corners,
then proceed to weld the perimeter of the reinforcement plate in sequence shown in Figure 2.
12. Remove weld blankets, if previously installed.
13. Spray undercoating on plate and welds being careful to avoid any overspray.
14. Reclip ABS sensor wire.
15. Repeat steps 6 through 14 for other side.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8138
16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist.
17. Connect battery negative cable.
18. Program radio stations.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page 8139
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8147
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock
Cylinder > Component Information > Service and Repair
Glove Compartment Lock Cylinder: Service and Repair
REMOVAL
1. Open glove compartment and remove lock cover. Remove four screws retaining lock cylinder. 2.
Remove lock cylinder from glove compartment.
INSTALLATION
1. To install, reverse Removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Customer Interest for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging
Headliner: Customer Interest Dome Lamp/Headliner - Sagging
Article No. 99-20-8
10/04/99
INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999
FORD: 1999-2000 CROWN VICTORIA
MERCURY: 1999-2000 GRAND MARQUIS
ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be
caused by the headliner material which was revised in the 1999 model to a less rigid material.
During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof
sheet metal prior to the adhesive curing.
ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof
sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an
adhesive attachment between the headliner and roof sheet metal. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
1. Remove the dome lamp lens.
2. Remove screws that secure the lamp assembly to the mounting bracket.
3. Disconnect the electrical connector to the lamp assembly.
4. Remove the black mounting bracket through the hole in the headliner.
5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty
knife to scrape off the adhesive.
6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The
adhesive should now be exposed.
7. Locate and align the new mounting bracket to the headliner opening.
NOTE
THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING.
8. Push the mounting bracket and headliner up against the roof.
NOTE:
SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE
BRACKET STAYS CORRECTLY LOCATED.
9. Connect electrical connector to the lamp assembly.
10. Locate the lamp assembly to the mounting bracket. Tighten screws.
11. Install dome lamp lens.
PART NUMBER PART NAME
F3MZ-5451 536-BA Bracket - Single Light
F5AZ-5451 536-BA Bracket - Dual Beam Light
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Customer Interest for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8160
OPERATION DESCRIPTION TIME
992008A Install New Headliner 0.3 Hr.
Bracket
DEALER CODING
CONDITION
BASIC PART NO. CODE
5451536 33
OASIS CODES: 105000, 107000, 201100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging
Headliner: All Technical Service Bulletins Dome Lamp/Headliner - Sagging
Article No. 99-20-8
10/04/99
INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999
FORD: 1999-2000 CROWN VICTORIA
MERCURY: 1999-2000 GRAND MARQUIS
ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be
caused by the headliner material which was revised in the 1999 model to a less rigid material.
During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof
sheet metal prior to the adhesive curing.
ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof
sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an
adhesive attachment between the headliner and roof sheet metal. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
1. Remove the dome lamp lens.
2. Remove screws that secure the lamp assembly to the mounting bracket.
3. Disconnect the electrical connector to the lamp assembly.
4. Remove the black mounting bracket through the hole in the headliner.
5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty
knife to scrape off the adhesive.
6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The
adhesive should now be exposed.
7. Locate and align the new mounting bracket to the headliner opening.
NOTE
THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING.
8. Push the mounting bracket and headliner up against the roof.
NOTE:
SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE
BRACKET STAYS CORRECTLY LOCATED.
9. Connect electrical connector to the lamp assembly.
10. Locate the lamp assembly to the mounting bracket. Tighten screws.
11. Install dome lamp lens.
PART NUMBER PART NAME
F3MZ-5451 536-BA Bracket - Single Light
F5AZ-5451 536-BA Bracket - Dual Beam Light
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Headliner: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging >
Page 8166
OPERATION DESCRIPTION TIME
992008A Install New Headliner 0.3 Hr.
Bracket
DEALER CODING
CONDITION
BASIC PART NO. CODE
5451536 33
OASIS CODES: 105000, 107000, 201100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Page 8167
Headliner: Service and Repair
REMOVAL
1. Remove the front seats.
2. Remove the front door weatherstrips.
3. Remove the windshield side garnish mouldings.
4. Disconnect the connector from the RH windshield pillar.
5. Remove the interior sun visors. 6. Remove the upper trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Page 8168
7. Remove the passenger assist handles. 8. Remove the upper trim panels.
9. Remove the pin-type retainers.
10. Using a hot knife or wide-blade putty knife, cut adhesive beads lengthwise across the
headliner.
NOTE: Pull down sides of headliner above the door openings to expose adhesive beads.
11. Remove the headliner through the front door opening.
NOTE: A new headliner must be installed if the headliner is folded in half for removal.
12. Clean any remaining adhesive from the roof sheet metal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: A new headliner will need to be installed if it is folded during removal or installation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and
Repair
Rear Shelf: Service and Repair
REMOVAL
1. Remove the rear seat cushion.
2. Remove the nut from each side. 3. Remove the seat backrest. 4. Remove the roof side rear trim
panels.
5. Remove the screw from each side.
6. Remove the high mounted stoplamp.
7. Remove the high mounted stoplamp brackets.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and
Repair > Page 8172
8. Remove the pin-type retainers. 9. Remove the package tray trim panel.
INSTALLATION
1. To install, reverse the removal procedure.
2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel
Trim Panel: Service and Repair B-Pillar Trim Panel
REMOVAL
1. Remove the front door scuff plate.
2. Remove the rear door scuff plate.
3. Pull back the front and rear door weatherstrips to clear the trim panels.
4. Remove the center body pillar lower finish panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 8177
5. Remove the center D-ring cover.
6. Remove the nut.
7. Remove the upper trim pillar.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 8178
Trim Panel: Service and Repair Quarter Trim Panel
REMOVAL
1. Remove the rear seat cushion.
2. Remove the nut from each side. 3. Remove the seat backrest.
4. Partially remove the weatherstrip to clear the roof side rear trim panel.
5. Remove the rear seat shoulder strap opening bezel.
6. Remove the pin-type retainer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 8179
7. Remove the bolt.
8. Remove the roof side rear trim panel.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Locks - Lock Service Packages Available
Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8186
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8187
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8188
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8189
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8190
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Technical Service Bulletins > Page 8191
Door Lock Cylinder: Description and Operation
Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Front Door
Door Lock Cylinder: Service and Repair Front Door
REMOVAL
1. Remove the exterior door handle.
NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and
building a new lock cylinder using a appropriate lock repair package. The lock repair package
includes a detailed instruction sheet to build the new lock cylinder to the current key code of the
vehicle.
2. Disconnect door lock cylinder rod.
3. Remove the clip.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and
building a new lock cylinder using a appropriate lock repair package. The lock repair package
includes a detailed instruction sheet to build the new lock cylinder to the current key code of the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Front Door > Page 8194
Door Lock Cylinder: Service and Repair Luggage Compartment Door
REMOVAL
1. Remove the nuts from each side
NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and
building a new lock cylinder using a appropriate lock repair package. The lock repair package
includes a detailed instruction sheet to build the new lock cylinder to the current key code of the
vehicle.
2. Disconnect the cable.
3. Disconnect the connectors.
4. Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Front Door > Page 8195
5. Remove the reflector lens assembly.
6. Remove the license lamp bulb.
7. Remove the rivets.
8. Remove the lock cylinder
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and
building a new lock cylinder using a appropriate lock repair package. The lock repair package
includes a detailed instruction sheet to build the new lock cylinder to the current key code of the
vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Diagrams > Page 8200
Keyless Entry Key-Pad: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door panel. 3. Position weathershield aside.
4. Remove the keyless entry keypad.
1 Remove the Clip.
^ Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair
Keyless Entry Transmitter: Service and Repair
1. Cycle the ignition from OFF to RUN four times within three seconds. The locks will then lock and
unlock, confirming program mode has been
entered.
2. Press any button on the transmitter to be programmed.
NOTE: When the first keyless entry remote transmitter is programmed, all other keyless entry
remote transmitters are erased.
3. If additional keyless entry remote transmitters are to be programmed, repeat step 2 within 7.5
seconds. 4. To exit program mode, turn the ignition to START or wait 7.5 seconds.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair
Power Door Lock Actuator: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the latch.
3. Pivot the actuator. 4. Remove the actuator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8212
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8213
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8214
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8215
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8216
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8217
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8218
Power Door Lock Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8219
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8220
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8221
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8222
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8223
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8224
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8225
Power Door Lock Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8226
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8227
Power Door Lock Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8228
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Diagram Information and Instructions > Page 8229
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Diagrams > Page 8230
Power Door Lock Control Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Master Window/Door Lock Control Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Master Window/Door Lock Control Switch > Page 8235
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > LF Door Lock Switch
Power Door Lock Switch: Testing and Inspection LF Door Lock Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > LF Door Lock Switch > Page 8238
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > LF Door Lock Switch > Page 8239
Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > LF Door Lock Switch > Page 8240
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Page 8241
Power Door Lock Switch: Service and Repair
REMOVAL
1. Remove the window regulator switch plate.
2. Remove the screws.
3. Disconnect the connector.
4. Remove the door lock switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical
Service Bulletins > Locks - Lock Service Packages Available
Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages
Available
Article No. 99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF
INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996
BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER,
RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000
WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES
LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000
NAVIGATOR
MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical
Service Bulletins > Locks - Lock Service Packages Available > Page 8246
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical
Service Bulletins > Locks - Lock Service Packages Available > Page 8247
This TSB article is being republished in its entirety to include vehicles, update model years, and
include a Lock Lever Kit Application Chart.
ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually.
Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks
must be replaced. The release of this TSB and associated parts will allow replacement of any
individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing
the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not
affected.
ACTION Lock service packages have been released that contain all the necessary components to
re-pin a new lock cylinder to the customer's current key code. It allows the service community to
replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For
removal and installation procedures for all lock cylinders, refer to the following Service Procedure
for details.
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT
LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF
THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE
10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING
THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical
Service Bulletins > Locks - Lock Service Packages Available > Page 8248
^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or
Workshop Manual, Section 211-04.
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop
Manual, Section 501-14.
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And
Usage Chart for correct application.
Determine the matching key cut depth at each key station (any of the following three methods may
be used to determine the key cut depth at each key station).
^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table
(the selling dealer should have the key code or the customer may be able to provide it). A key code
table comes with the Rotunda Key Cutter (011-00215).
^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda
Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61).
Equivalent decoders are commonly available through the locksmith industry. A key decoder is a
plate with an elongated slot corresponding to the different key cut heights.
^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the
instruction sheet contained within each lock service package.
One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the
cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is
rebuilt properly before it's installed in the vehicle.
Each lock service package will include a unique detailed instruction sheet on how to re-pin that
individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800)
826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian
dealers only).
For technical questions regarding the lock service pack re-pinning process, call Ford Interior
Systems at (313) 337-3041.
A special service tool is required to properly install (crimp) the round dust covers on the door lock
cylinder. This special service tool has been provided through a special mailing to all North
American servicing dealers. If additional tools are required, contact Rotunda Tools at (800)
768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool
(501-O51A).
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE
DOOR LOCK CYLINDER ROUND DUST COVERS.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical
Service Bulletins > Locks - Lock Service Packages Available > Page 8249
A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to
service any vehicle is also required to complete this repair. This kit contains levers to service
numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim
form. This will automatically generate a unit lever price. For an application chart that lists the usage
of all levers included in the kit, refer to Figure 1.
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN
SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING
LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE
UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE
UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467)
AND A LABEL FOR THE BOX) AND THE UPDATE
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Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical
Service Bulletins > Locks - Lock Service Packages Available > Page 8250
E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND
A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT
(F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT
(XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND
LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER.
THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS
NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED
TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front
door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks
(sliding door, liftgate and ignition) can be serviced using the lock service packages.
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 112000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions
Power Mirror Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8256
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8257
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8258
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8259
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8260
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8261
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8262
Power Mirror Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8263
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8264
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8265
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8266
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8267
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8268
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8269
Power Mirror Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8270
Driver's Door Module (C520)
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams
> Diagram Information and Instructions > Page 8271
Power Mirror Control Module: Electrical Diagrams
Diagram 57-1
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> Diagram Information and Instructions > Page 8272
Diagram 57-2
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> Diagram Information and Instructions > Page 8273
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
Power Mirror Motor: Service and Repair
REMOVAL
1. Remove the exterior rear view mirror.
2. Push in the upper edge of the exterior rear view mirror glass to the maximum travel and gently
pull outward until the exterior rear view mirror
glass is released.
3. Remove the screws.
4. Remove the motor.
NOTE: Note the colors and locations of the connectors prior to removal.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams
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8280
Power Mirror Switch: Testing and Inspection
Component Testing Procedure
Terminals
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8281
Schematic
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8282
Power Mirror Switch: Service and Repair
REMOVAL
1. Remove the window regulator switch plate from the front door trim panel.
CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or
damage to the front door trim panel may occur.
2. Release the tabs.
3. Remove the exterior rear view mirror control switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture
Technical Service Bulletin # 99-12-10 Date: 990614
Paint - Rough Texture
Article No. 99-12-10
06/14/99
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR
LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F
SERIES
MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES,
LOUISVILLE
This TSB article is being republished in its entirety to add vehicles and model years, and to revise
the procedure to use Ford brand service parts.
ISSUE Ford Motor Company has released a private labeled material to be used for iron
particle/acid rain service repairs.
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8292
ACTION To remove these particles/contaminates, use ONLY the following products and procedure.
No polishing, compounding, color sanding, or repainting should be done before this procedure is
performed. This procedure uses products that are acidic, alkaline, and neutral and must be
properly mixed and used in their specific order. Refer to the following Service Procedure for details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8293
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-21-3
WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
991210A Decontaminate And 0.6 Hr.
Surface Correction (Aspire, F-450/550, And Cargo)
991210B Decontaminate And 0.7 Hr.
Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar)
991210C Decontaminate And 0.8 Hr.
Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang
Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999
Cougar)
991210D Decontaminate And 0.8 Hr.
Surface Correction (F-Series And 1996-97 Thunderbird/Cougar)
991210E Decontaminate And 0.8 Hr.
Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax)
991210F Decontaminate And 0.9 Hr.
Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab,
Explorer 2-Door, And 1999 Villager)
991210G Decontaminate And 0.9 Hr.
Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed -
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8294
Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular
Cab)
991210H Decontaminate And 1.0 Hr.
Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And
Mountaineer)
9912101 Decontaminate And 1.0 Hr.
Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator)
991210J Decontaminate And 1.2 Hrs.
Surface Correction (Econoline Wagon/Wagon Super-V)
991210k Decontaminate And 1.3 Hrs.
Surface Correction (Econoline Cargo)
991210L Decontaminate And 1.4 Hrs.
Surface Correction (Econoline Cargo Super-V)
DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY
CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES.
NOTE
THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE
DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120
DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE
PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS
COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING
PROCEDURES AFTER VEHICLE INSPECTION.
Identification
Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc.
These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature
combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron
to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive
compounds that fall on the vehicle's painted surfaces. When subjected to moisture and
temperature, chemical compounds are created that etch the paint surface. To assist in identitying
surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier.
Concern Description
Ferrous Metal
Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is
rough to the touch.
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Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8295
Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The
surface is rough to the touch.
Industrial Fallout
Water spots with ferrous metal are present and the surface is rough to the touch.
Acid Rain/Etching
^ Surface will exhibit irregular discolored spotting.
^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the
paint.
^ Extreme cases of etching will be visible and may be felt.
Decontamination Procedure
Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize
the paint surface. Perform the procedure only on vehicle when the paint surface temperature is
cool. Follow the step-by-step procedure listed below to perform this service operation.
1. Rinse off dust, dirt, and debris with cold water. Flush liberally.
2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket.
3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the
top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5
to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes.
NOTE
USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS.
4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer.
5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass.
6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser
squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline
Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and
lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8
minutes.
7. Rinse the vehicle thoroughly with cold water.
8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water.
9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water
and dry the vehicle completely.
NOTE
DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE
USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS.
Surface Correction Following Decontam./Neutralization
1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots.
NOTE
ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES
DEPENDENT ON DEPTH OF DAMAGE;
POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING.
2. Do Not Intermix Buffing Products. Use only one manufacturer's products.
3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended
pad at recommended buffing speeds as specified by the product manufacturer.
NOTE
WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING,
DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE
REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY
RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL.
4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove
any swirls created by a rotary buffer or pad.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8296
5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of
scratches and swirls before application of the final polish.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture
Technical Service Bulletin # 99-12-10 Date: 990614
Paint - Rough Texture
Article No. 99-12-10
06/14/99
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR
LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F
SERIES
MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES,
LOUISVILLE
This TSB article is being republished in its entirety to add vehicles and model years, and to revise
the procedure to use Ford brand service parts.
ISSUE Ford Motor Company has released a private labeled material to be used for iron
particle/acid rain service repairs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8302
ACTION To remove these particles/contaminates, use ONLY the following products and procedure.
No polishing, compounding, color sanding, or repainting should be done before this procedure is
performed. This procedure uses products that are acidic, alkaline, and neutral and must be
properly mixed and used in their specific order. Refer to the following Service Procedure for details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8303
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-21-3
WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
991210A Decontaminate And 0.6 Hr.
Surface Correction (Aspire, F-450/550, And Cargo)
991210B Decontaminate And 0.7 Hr.
Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar)
991210C Decontaminate And 0.8 Hr.
Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang
Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999
Cougar)
991210D Decontaminate And 0.8 Hr.
Surface Correction (F-Series And 1996-97 Thunderbird/Cougar)
991210E Decontaminate And 0.8 Hr.
Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax)
991210F Decontaminate And 0.9 Hr.
Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab,
Explorer 2-Door, And 1999 Villager)
991210G Decontaminate And 0.9 Hr.
Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed -
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8304
Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular
Cab)
991210H Decontaminate And 1.0 Hr.
Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And
Mountaineer)
9912101 Decontaminate And 1.0 Hr.
Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator)
991210J Decontaminate And 1.2 Hrs.
Surface Correction (Econoline Wagon/Wagon Super-V)
991210k Decontaminate And 1.3 Hrs.
Surface Correction (Econoline Cargo)
991210L Decontaminate And 1.4 Hrs.
Surface Correction (Econoline Cargo Super-V)
DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY
CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES.
NOTE
THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE
DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120
DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE
PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS
COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING
PROCEDURES AFTER VEHICLE INSPECTION.
Identification
Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc.
These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature
combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron
to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive
compounds that fall on the vehicle's painted surfaces. When subjected to moisture and
temperature, chemical compounds are created that etch the paint surface. To assist in identitying
surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier.
Concern Description
Ferrous Metal
Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is
rough to the touch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8305
Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The
surface is rough to the touch.
Industrial Fallout
Water spots with ferrous metal are present and the surface is rough to the touch.
Acid Rain/Etching
^ Surface will exhibit irregular discolored spotting.
^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the
paint.
^ Extreme cases of etching will be visible and may be felt.
Decontamination Procedure
Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize
the paint surface. Perform the procedure only on vehicle when the paint surface temperature is
cool. Follow the step-by-step procedure listed below to perform this service operation.
1. Rinse off dust, dirt, and debris with cold water. Flush liberally.
2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket.
3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the
top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5
to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes.
NOTE
USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS.
4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer.
5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass.
6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser
squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline
Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and
lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8
minutes.
7. Rinse the vehicle thoroughly with cold water.
8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water.
9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water
and dry the vehicle completely.
NOTE
DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE
USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS.
Surface Correction Following Decontam./Neutralization
1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots.
NOTE
ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES
DEPENDENT ON DEPTH OF DAMAGE;
POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING.
2. Do Not Intermix Buffing Products. Use only one manufacturer's products.
3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended
pad at recommended buffing speeds as specified by the product manufacturer.
NOTE
WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING,
DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE
REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY
RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL.
4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove
any swirls created by a rotary buffer or pad.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 8306
5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of
scratches and swirls before application of the final polish.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8307
Paint: By Symptom
Technical Service Bulletin # 99-12-10 Date: 990614
Paint - Rough Texture
Article No. 99-12-10
06/14/99
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR
LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F
SERIES
MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES,
LOUISVILLE
This TSB article is being republished in its entirety to add vehicles and model years, and to revise
the procedure to use Ford brand service parts.
ISSUE Ford Motor Company has released a private labeled material to be used for iron
particle/acid rain service repairs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8308
ACTION To remove these particles/contaminates, use ONLY the following products and procedure.
No polishing, compounding, color sanding, or repainting should be done before this procedure is
performed. This procedure uses products that are acidic, alkaline, and neutral and must be
properly mixed and used in their specific order. Refer to the following Service Procedure for details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8309
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-21-3
WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
991210A Decontaminate And 0.6 Hr.
Surface Correction (Aspire, F-450/550, And Cargo)
991210B Decontaminate And 0.7 Hr.
Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar)
991210C Decontaminate And 0.8 Hr.
Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang
Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999
Cougar)
991210D Decontaminate And 0.8 Hr.
Surface Correction (F-Series And 1996-97 Thunderbird/Cougar)
991210E Decontaminate And 0.8 Hr.
Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax)
991210F Decontaminate And 0.9 Hr.
Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab,
Explorer 2-Door, And 1999 Villager)
991210G Decontaminate And 0.9 Hr.
Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed -
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8310
Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular
Cab)
991210H Decontaminate And 1.0 Hr.
Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And
Mountaineer)
9912101 Decontaminate And 1.0 Hr.
Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator)
991210J Decontaminate And 1.2 Hrs.
Surface Correction (Econoline Wagon/Wagon Super-V)
991210k Decontaminate And 1.3 Hrs.
Surface Correction (Econoline Cargo)
991210L Decontaminate And 1.4 Hrs.
Surface Correction (Econoline Cargo Super-V)
DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY
CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES.
NOTE
THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE
DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120
DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE
PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS
COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING
PROCEDURES AFTER VEHICLE INSPECTION.
Identification
Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc.
These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature
combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron
to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive
compounds that fall on the vehicle's painted surfaces. When subjected to moisture and
temperature, chemical compounds are created that etch the paint surface. To assist in identitying
surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier.
Concern Description
Ferrous Metal
Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is
rough to the touch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8311
Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The
surface is rough to the touch.
Industrial Fallout
Water spots with ferrous metal are present and the surface is rough to the touch.
Acid Rain/Etching
^ Surface will exhibit irregular discolored spotting.
^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the
paint.
^ Extreme cases of etching will be visible and may be felt.
Decontamination Procedure
Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize
the paint surface. Perform the procedure only on vehicle when the paint surface temperature is
cool. Follow the step-by-step procedure listed below to perform this service operation.
1. Rinse off dust, dirt, and debris with cold water. Flush liberally.
2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket.
3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the
top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5
to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes.
NOTE
USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS.
4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer.
5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass.
6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser
squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline
Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and
lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8
minutes.
7. Rinse the vehicle thoroughly with cold water.
8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water.
9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water
and dry the vehicle completely.
NOTE
DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE
USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS.
Surface Correction Following Decontam./Neutralization
1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots.
NOTE
ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES
DEPENDENT ON DEPTH OF DAMAGE;
POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING.
2. Do Not Intermix Buffing Products. Use only one manufacturer's products.
3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended
pad at recommended buffing speeds as specified by the product manufacturer.
NOTE
WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING,
DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE
REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY
RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL.
4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove
any swirls created by a rotary buffer or pad.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8312
5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of
scratches and swirls before application of the final polish.
Technical Service Bulletin # 99-12-10 Date: 990614
Paint - Rough Texture
Article No. 99-12-10
06/14/99
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL,
GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR
LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F
SERIES
MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES,
LOUISVILLE
This TSB article is being republished in its entirety to add vehicles and model years, and to revise
the procedure to use Ford brand service parts.
ISSUE Ford Motor Company has released a private labeled material to be used for iron
particle/acid rain service repairs.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8313
ACTION To remove these particles/contaminates, use ONLY the following products and procedure.
No polishing, compounding, color sanding, or repainting should be done before this procedure is
performed. This procedure uses products that are acidic, alkaline, and neutral and must be
properly mixed and used in their specific order. Refer to the following Service Procedure for details.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8314
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-21-3
WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
991210A Decontaminate And 0.6 Hr.
Surface Correction (Aspire, F-450/550, And Cargo)
991210B Decontaminate And 0.7 Hr.
Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar)
991210C Decontaminate And 0.8 Hr.
Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang
Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999
Cougar)
991210D Decontaminate And 0.8 Hr.
Surface Correction (F-Series And 1996-97 Thunderbird/Cougar)
991210E Decontaminate And 0.8 Hr.
Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax)
991210F Decontaminate And 0.9 Hr.
Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab,
Explorer 2-Door, And 1999 Villager)
991210G Decontaminate And 0.9 Hr.
Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed -
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8315
Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular
Cab)
991210H Decontaminate And 1.0 Hr.
Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And
Mountaineer)
9912101 Decontaminate And 1.0 Hr.
Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator)
991210J Decontaminate And 1.2 Hrs.
Surface Correction (Econoline Wagon/Wagon Super-V)
991210k Decontaminate And 1.3 Hrs.
Surface Correction (Econoline Cargo)
991210L Decontaminate And 1.4 Hrs.
Surface Correction (Econoline Cargo Super-V)
DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY
CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES.
NOTE
THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE
DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120
DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE
PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS
COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING
PROCEDURES AFTER VEHICLE INSPECTION.
Identification
Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc.
These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature
combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron
to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive
compounds that fall on the vehicle's painted surfaces. When subjected to moisture and
temperature, chemical compounds are created that etch the paint surface. To assist in identitying
surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier.
Concern Description
Ferrous Metal
Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is
rough to the touch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8316
Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The
surface is rough to the touch.
Industrial Fallout
Water spots with ferrous metal are present and the surface is rough to the touch.
Acid Rain/Etching
^ Surface will exhibit irregular discolored spotting.
^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the
paint.
^ Extreme cases of etching will be visible and may be felt.
Decontamination Procedure
Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize
the paint surface. Perform the procedure only on vehicle when the paint surface temperature is
cool. Follow the step-by-step procedure listed below to perform this service operation.
1. Rinse off dust, dirt, and debris with cold water. Flush liberally.
2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket.
3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the
top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5
to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes.
NOTE
USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS.
4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer.
5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass.
6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser
squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline
Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and
lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8
minutes.
7. Rinse the vehicle thoroughly with cold water.
8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water.
9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water
and dry the vehicle completely.
NOTE
DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE
USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS.
Surface Correction Following Decontam./Neutralization
1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots.
NOTE
ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES
DEPENDENT ON DEPTH OF DAMAGE;
POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING.
2. Do Not Intermix Buffing Products. Use only one manufacturer's products.
3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended
pad at recommended buffing speeds as specified by the product manufacturer.
NOTE
WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING,
DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE
REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY
RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL.
4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove
any swirls created by a rotary buffer or pad.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > Page 8317
5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of
scratches and swirls before application of the final polish.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8323
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8324
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8325
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8326
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8327
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8328
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8329
Power Door Lock Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8330
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8331
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8332
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8333
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8334
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8335
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8336
Power Door Lock Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8337
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8338
Power Door Lock Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8339
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8340
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Diagrams > Page 8341
Power Door Lock Control Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Power Mirror Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8346
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8347
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8348
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8349
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8350
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8351
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8352
Power Mirror Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8353
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8354
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8355
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8356
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8357
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8358
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8359
Power Mirror Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8360
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8361
Power Mirror Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8362
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8363
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Power Seat Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8368
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8369
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8370
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8371
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8372
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8373
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8374
Power Seat Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8375
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8376
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8377
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8378
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8379
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8380
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8381
Power Seat Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8382
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8383
Power Seat Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8384
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 8385
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions
Power Seat Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8391
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8392
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8393
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8394
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8395
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8396
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8397
Power Seat Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8398
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8399
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8400
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8401
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8402
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8403
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8404
Power Seat Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8405
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8406
Power Seat Control Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8407
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 8408
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's
Seat Motor Assembly
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's
Seat Motor Assembly > Page 8413
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page
8414
Power Seat Motor: Service and Repair
REMOVAL
1. Remove the seat. 2. Remove the seat track.
3. Disconnect the connector.
4. Disconnect the hose.
5. Remove the lumbar motor.
INSTALLATION
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's
Seat Control Switch
Power Seat Switch: Diagrams Driver's Seat Control Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's
Seat Control Switch > Page 8419
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch
Power Seat Switch: Testing and Inspection Driver's Seat Control Switch
Driver Seat Control Switch (All Others)
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch > Page 8422
Schematic
Driver Seat Control Switch (Base and Police)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch > Page 8423
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch > Page 8424
Terminals
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch > Page 8425
Power Seat Switch: Testing and Inspection Passenger Seat Control Switch
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch > Page 8426
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Driver's Seat Control Switch > Page 8427
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Front Seat Occupied Switch
Power Seat Switch: Service and Repair Front Seat Occupied Switch
REMOVAL
1. Disconnect the battery. 2. Remove the seat. 3. Remove the seat track.
4. Disconnect the connector.
5. Slide the retainers outboard.
6. Remove the switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Front Seat Occupied Switch > Page 8430
Power Seat Switch: Service and Repair Lumbar Seat Control Switch
REMOVAL
1. Disconnect the battery. 2. Remove the seat.
3. Remove the cover.
4. Remove the screws.
5. Disconnect the connector.
6. Disconnect the vacuum tubes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Front Seat Occupied Switch > Page 8431
NOTE: Mark the tubes before disconnecting.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Front Seat Occupied Switch > Page 8432
Power Seat Switch: Service and Repair Seat Regulator Control Switch
REMOVAL
1. Disconnect the battery. 2. Remove the front door trim panel.
3. Remove the seat regulator control switch.
1 Remove the screws.
2 Remove the switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair
Seat Cushion: Service and Repair
DISASSEMBLY
1. Remove the seat. 2. Remove the seat track. 3. Remove the lumbar motor.
4. Release the retainers.
1 Release the J retainers.
2 Remove the pin-type retainer.
5. Remove the cover.
6. Remove the retaining clip.
7. Remove the pin. 8. Remove the armrest.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Page 8436
9. Remove the armrest cover trim.
10. Remove the frame.
11. Remove the bolts. 12. Remove the seat occupy switch.
13. Remove the seat trim cover.
ASSEMBLY
1. To install, reverse the disassembly procedure. 2. Check the restraint system for correct
operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Description and Operation
Seat Latch: Description and Operation
WARNING: THE INERTIA FRONT SEAT BACKREST LATCH ASSEMBLY IS
FACTORY-INSTALLED IN ITS CORRECT LOCATION. CUSTOMER OR DEALER
MAINTENANCE IS NOT REQUIRED. CORRECT FRONT SEAT BACKREST LATCH FUNCTION
IN EMERGENCY SITUATIONS REQUIRES THAT THE SEAT BACKREST BE IN ITS FULL
REARWARD NORMAL POSITION AND AGAINST THE REARWARD STOPS IN THE FRONT
SEAT BACKREST LATCH ASSEMBLY. THEREFORE, THE AREA BEHIND THE SEAT MUST BE
KEPT CLEAR AT ALL TIMES TO ALLOW FULL REARWARD TRAVEL OF THE SEAT
BACKREST. IN ADDITION, REAR SEAT PASSENGERS SHOULD NOT LEAN ON THE FRONT
SEAT BACKREST WHILE THE VEHICLE IS IN MOTION. THE FORWARD FORCE ON THE
SEAT BACKREST FROM THE REAR PASSENGER IN AN EMERGENCY SITUATION MAY
PREVENT CORRECT OPERATION OF THE INERTIA FRONT SEAT BACKREST LATCH
MECHANISM.
NOTE: The front seat backrest latch must be installed as new if any component is non-functional or
damaged.
^ The inertia front seat backrest latch remains unlocked with normal usage, and locks only during
vehicle deceleration (emergency stopping or upon impact) or on steep downhill grades.
^ A manual (override) release handle is provided only to help unlock the front seat backrest latch in
the event of front seat backrest latch lockup.
The only authorized repair of the front seat backrest latch includes:
^ tightening of the retaining screws to the correct specification
^ installing a new front seat backrest latch
^ removal of any foreign material, such as tie straps, pieces of foam and trim
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only
Seat Track: Service and Repair Driver Side Only
REMOVAL
CAUTION: Use care when handling the seat and track assembly. dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
1. Remoce the front seat.
2. Disconnect the connector.
3. Remove the nut. 4. Pull the buckle through the cushion opening.
5. Release the J retainer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only > Page 8444
6. Release the J retainer.
7. Remove the bolts.
8. Remove the pivot bolt.
9. Disconnect the connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only > Page 8445
10. Remove the bolts.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only > Page 8446
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only > Page 8447
Seat Track: Service and Repair Except Driver Side
REMOVAL
CAUTION: Use care when handling the seat and track assembly. dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
1. Remove the front seat.
2. Remove the nut. 3. Pull the buckle through the cushion opening.
4. Release the J retainer.
5. Release the J retainer.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only > Page 8448
6. Remove the bolts.
7. Remove the pivot bolt.
8. Disconnect the connector.
9. Remove the bolts.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver
Side Only > Page 8449
1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Fuel Door Lock Switch >
Component Information > Description and Operation
Fuel Door Lock Switch: Description and Operation
The fuel filler door lock switch:
- actuates a solenoid integral to the fuel filler door latch to release the fuel filler door.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated
Replacement Part
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement
Part
Article No. 01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES
1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION
LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD
MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree
Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical
switches will be available as a service replacement.
ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury
switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate
model year Workshop Manual as needed.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 201000, 201200
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 8463
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch
Power Door Lock Switch: Testing and Inspection LF Door Lock Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch > Page 8466
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch > Page 8467
Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > LF Door Lock Switch > Page 8468
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Page 8469
Power Door Lock Switch: Service and Repair
REMOVAL
1. Remove the window regulator switch plate.
2. Remove the screws.
3. Disconnect the connector.
4. Remove the door lock switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 8473
Power Mirror Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 8474
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 8475
Power Mirror Switch: Service and Repair
REMOVAL
1. Remove the window regulator switch plate from the front door trim panel.
CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or
damage to the front door trim panel may occur.
2. Release the tabs.
3. Remove the exterior rear view mirror control switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Driver's Seat Control Switch
Power Seat Switch: Diagrams Driver's Seat Control Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Driver's Seat Control Switch > Page 8480
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch
Power Seat Switch: Testing and Inspection Driver's Seat Control Switch
Driver Seat Control Switch (All Others)
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch > Page 8483
Schematic
Driver Seat Control Switch (Base and Police)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch > Page 8484
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch > Page 8485
Terminals
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch > Page 8486
Power Seat Switch: Testing and Inspection Passenger Seat Control Switch
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch > Page 8487
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Driver's Seat Control Switch > Page 8488
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Front Seat Occupied Switch
Power Seat Switch: Service and Repair Front Seat Occupied Switch
REMOVAL
1. Disconnect the battery. 2. Remove the seat. 3. Remove the seat track.
4. Disconnect the connector.
5. Slide the retainers outboard.
6. Remove the switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Front Seat Occupied Switch > Page 8491
Power Seat Switch: Service and Repair Lumbar Seat Control Switch
REMOVAL
1. Disconnect the battery. 2. Remove the seat.
3. Remove the cover.
4. Remove the screws.
5. Disconnect the connector.
6. Disconnect the vacuum tubes.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Front Seat Occupied Switch > Page 8492
NOTE: Mark the tubes before disconnecting.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Front Seat Occupied Switch > Page 8493
Power Seat Switch: Service and Repair Seat Regulator Control Switch
REMOVAL
1. Disconnect the battery. 2. Remove the front door trim panel.
3. Remove the seat regulator control switch.
1 Remove the screws.
2 Remove the switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises
Technical Service Bulletin # 99-6-5 Date: 990405
Side Doors - Wind Noises
Article No. 99-6-5
04/05/99
WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS
FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR
LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1995-99 MYSTIQUE
LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER
1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150,
NAVIGATOR 1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to add model year coverage and specify a
standard door weatherstrip service push pin.
ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the
door weatherstrip seal. This TSB article provides Service Tips for correcting this concern.
ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following
Windnoise Service Tips.
PART NUMBER PART NAME
E8AZ-19552-A Weatherstrip And Rubber Adhesive
E8AZ-19554-A Instant Adhesive
N806340-S Snap-On Push Pin
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-18-5
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 110000, 701000
Windnoise Service Tips
DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS:
^ Torn
^ Ripped
^ Cut
^ Deteriorated excessively
^ Material defect/abnormalities, or
^ TSB specifies the replacement of the weatherstrip
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8502
NOTE
REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE.
Weatherstrip Windnoise or Appearance Service Tips
The following text explains attachment methods for Ford Motor Company's generic repair
standards for loose and/or misaligned weatherstrips.
Flanges
are typically used on the body opening where weatherstrip retention fins grab onto each side of the
sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips
become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back
onto the sheet metal flange and stretching to provide better retention around corners. If the
weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section
be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once
replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber
Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be
applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper
retention force.
Sheet Metal C-Channels
are typically used on the upper perimeter of the door assembly or body panel to hold the
weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the
channel, repair by first removing the weatherstrip from the entire channel, and reassemble by
sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is
also required that the C-channel be carefully bent back into the proper shape to retain the
weatherstrip molded base.
Push Pins
are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They
are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the
actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is
damaged, it should be replaced by first removing the existing push pin. Then, the base of a new
push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding
sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard
N806340-S.
Rivets
are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes
loose, the entire rivet should be removed and replaced with a new rivet.
Adhesive Tape
is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces
must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should
be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or
equivalent).
Verification
1. If the weatherstrip is not attached properly, reattach it correctly.
2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to
diagnose the root cause of the windnoise. Verify the sealing contact between the door and the
weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article.
3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise,
readjust the doors to contact the weatherstrips.
NOTE
WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING
EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR
SYSTEM.
3X5" Card Test
1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door
closed.
2. Run the card up along the A-pillar.
If the card easily moves at any location along the A-pillar, then the sealing contact between the
door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing
contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To
evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be
performed.
Chalk Test
1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing
powder (chalk spray).
2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an
inaccurate reading).
3. Open the door and inspect the seals for degree of compression and possible skips.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8503
To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a
tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder
footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the
door should be adjusted to increase the sealing contact.
Door Adjusting
Refer to Figures 1 and 2.
1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact
with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly
correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be
loosened and adjusted to perform the alignment procedure. Note that the door striker only controls
the in/out location of the door at the rear latch area. The hinges control the in/out location of the
door at the front, and the overall tip or tilt of the door when viewed from the front or rear.
2. Review the overall fit of the door to the surrounding panels, and the amount of compression of
the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially
from the rear of the vehicle to the front:
^ from the quarter panel to the rear door
^ from the rear door to the front door
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8504
^ then the front door to the fender
All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door
to the quarter panel and working forward.
3. The door should be adjusted to obtain proper seal compression while maintaining a good door
fit. An adjustment may be required only at one hinge. For example: if the top of the door is
outboard, causing a lack of seal compression around the upper door frame area, and the fit of the
lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge
would be appropriate (refer to Step 5). Note that adjustments to the rear door may require
additional adjustments to the front door, and then also possibly to the front fender to maintain the
proper panel fit and alignment.
4. The rear of the door should be set in/out with the striker to align at the door latch area with the
mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount
of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower
surfaces of the door aligned or flushed to the adjacent panels.
5. The in/out setting at the front of the doors is controlled by the hinge adjustment.
^ It should be set to obtain the proper amount of seal contact, which can be determined using the
3X5" Card Test or the Chalk Test.
^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be
adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to
permit movement of the door with a padded pry bar.
^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic
door movement (which may result due to the weight of the door) which will result in a complete
door refitting for both up/down as well as in/out positions.
^ The amount of movement can be determined by outlining the hinge mounting area on the door
prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A
2-4mm adjustment should be sufficient to return the door to within its nominal operating range.
6. Finally, the door closing effort should be checked to be sure the seal compression has not
increased so much that a closing effort concern has been created. If the efforts are unacceptably
high, the door may have been moved excessively inward, and should be refitted outward to a
location that balances the seal compression for windnoise with closing efforts. It may be necessary
to perform another 3X5" Card Test or Chalk Test to verify the final seal compression.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification
Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Replacement Identification
Article No 99-13-12
06/28/99
DOOR - IDENTIFYING CORRECT REPLACEMENT DOOR WEATHERSTRIP
FORD: 1999 CROWN VICTORIA
MERCURY: 1999 GRAND MARQUIS
ISSUE This article is published to help identify correct replacement 1999 model door sealing
weatherstrip. A mid-year change to improve the door sealing weatherstrips introduced new seals.
Parts affected include the primary seal on the doors, weatherstrip seal on the door opening, and
the roof side weatherstrip
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification >
Page 8510
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification >
Page 8511
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification >
Page 8512
ACTION Correctly identify the weatherstrip on the vehicle and assist in determining replacement
parts. Figures 1, 2 and 3 provide cross-sections of the original and new weatherstrips and should
be used for comparison. The following Tables should be used to determine the correct service
replacement part.
NOTE
MIXING ORIGINAL AND NEW PARTS CAN CAUSE WINDNOISE DEGRADATION OR HIGH
DOOR CLOSING EFFORTS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 110000, 701000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises
Technical Service Bulletin # 99-6-5 Date: 990405
Side Doors - Wind Noises
Article No. 99-6-5
04/05/99
WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS
FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR
LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE,
TOWN CAR, TRACER 1995-99 MYSTIQUE
LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER
1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150,
NAVIGATOR 1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to add model year coverage and specify a
standard door weatherstrip service push pin.
ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the
door weatherstrip seal. This TSB article provides Service Tips for correcting this concern.
ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following
Windnoise Service Tips.
PART NUMBER PART NAME
E8AZ-19552-A Weatherstrip And Rubber Adhesive
E8AZ-19554-A Instant Adhesive
N806340-S Snap-On Push Pin
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-18-5
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 110000, 701000
Windnoise Service Tips
DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS:
^ Torn
^ Ripped
^ Cut
^ Deteriorated excessively
^ Material defect/abnormalities, or
^ TSB specifies the replacement of the weatherstrip
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8517
NOTE
REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE.
Weatherstrip Windnoise or Appearance Service Tips
The following text explains attachment methods for Ford Motor Company's generic repair
standards for loose and/or misaligned weatherstrips.
Flanges
are typically used on the body opening where weatherstrip retention fins grab onto each side of the
sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips
become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back
onto the sheet metal flange and stretching to provide better retention around corners. If the
weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section
be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once
replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber
Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be
applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper
retention force.
Sheet Metal C-Channels
are typically used on the upper perimeter of the door assembly or body panel to hold the
weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the
channel, repair by first removing the weatherstrip from the entire channel, and reassemble by
sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is
also required that the C-channel be carefully bent back into the proper shape to retain the
weatherstrip molded base.
Push Pins
are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They
are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the
actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is
damaged, it should be replaced by first removing the existing push pin. Then, the base of a new
push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding
sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard
N806340-S.
Rivets
are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes
loose, the entire rivet should be removed and replaced with a new rivet.
Adhesive Tape
is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces
must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should
be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or
equivalent).
Verification
1. If the weatherstrip is not attached properly, reattach it correctly.
2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to
diagnose the root cause of the windnoise. Verify the sealing contact between the door and the
weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article.
3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise,
readjust the doors to contact the weatherstrips.
NOTE
WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING
EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR
SYSTEM.
3X5" Card Test
1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door
closed.
2. Run the card up along the A-pillar.
If the card easily moves at any location along the A-pillar, then the sealing contact between the
door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing
contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To
evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be
performed.
Chalk Test
1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing
powder (chalk spray).
2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an
inaccurate reading).
3. Open the door and inspect the seals for degree of compression and possible skips.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8518
To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a
tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder
footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the
door should be adjusted to increase the sealing contact.
Door Adjusting
Refer to Figures 1 and 2.
1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact
with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly
correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be
loosened and adjusted to perform the alignment procedure. Note that the door striker only controls
the in/out location of the door at the rear latch area. The hinges control the in/out location of the
door at the front, and the overall tip or tilt of the door when viewed from the front or rear.
2. Review the overall fit of the door to the surrounding panels, and the amount of compression of
the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially
from the rear of the vehicle to the front:
^ from the quarter panel to the rear door
^ from the rear door to the front door
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8519
^ then the front door to the fender
All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door
to the quarter panel and working forward.
3. The door should be adjusted to obtain proper seal compression while maintaining a good door
fit. An adjustment may be required only at one hinge. For example: if the top of the door is
outboard, causing a lack of seal compression around the upper door frame area, and the fit of the
lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge
would be appropriate (refer to Step 5). Note that adjustments to the rear door may require
additional adjustments to the front door, and then also possibly to the front fender to maintain the
proper panel fit and alignment.
4. The rear of the door should be set in/out with the striker to align at the door latch area with the
mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount
of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower
surfaces of the door aligned or flushed to the adjacent panels.
5. The in/out setting at the front of the doors is controlled by the hinge adjustment.
^ It should be set to obtain the proper amount of seal contact, which can be determined using the
3X5" Card Test or the Chalk Test.
^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be
adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to
permit movement of the door with a padded pry bar.
^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic
door movement (which may result due to the weight of the door) which will result in a complete
door refitting for both up/down as well as in/out positions.
^ The amount of movement can be determined by outlining the hinge mounting area on the door
prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A
2-4mm adjustment should be sufficient to return the door to within its nominal operating range.
6. Finally, the door closing effort should be checked to be sure the seal compression has not
increased so much that a closing effort concern has been created. If the efforts are unacceptably
high, the door may have been moved excessively inward, and should be refitted outward to a
location that balances the seal compression for windnoise with closing efforts. It may be necessary
to perform another 3X5" Card Test or Chalk Test to verify the final seal compression.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification
Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Replacement Identification
Article No 99-13-12
06/28/99
DOOR - IDENTIFYING CORRECT REPLACEMENT DOOR WEATHERSTRIP
FORD: 1999 CROWN VICTORIA
MERCURY: 1999 GRAND MARQUIS
ISSUE This article is published to help identify correct replacement 1999 model door sealing
weatherstrip. A mid-year change to improve the door sealing weatherstrips introduced new seals.
Parts affected include the primary seal on the doors, weatherstrip seal on the door opening, and
the roof side weatherstrip
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page
8525
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page
8526
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Weatherstrip: > 99-13-12 > Jun > 99 > Door Weatherstrip - Replacement Identification > Page
8527
ACTION Correctly identify the weatherstrip on the vehicle and assist in determining replacement
parts. Figures 1, 2 and 3 provide cross-sections of the original and new weatherstrips and should
be used for comparison. The following Tables should be used to determine the correct service
replacement part.
NOTE
MIXING ORIGINAL AND NEW PARTS CAN CAUSE WINDNOISE DEGRADATION OR HIGH
DOOR CLOSING EFFORTS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 110000, 701000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component
Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component
Information > Diagrams > Page 8532
Deactivator Switch: Adjustments
NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component
Information > Service and Repair > Brake Pedal Position (BPP) Switch
Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the lower insulator.
1 Remove the push pins.
2 Disconnect the interior lamp.
3 Remove the lower insulator.
3. Disconnect the Brake Pedal Position (BPP) switch.
4. Remove the BPP switch.
1 Remove the cotter pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component
Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8535
2 Remove the sleeve.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component
Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8536
Deactivator Switch: Service and Repair Deactivator Switch
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the deactivator switch.
1 Disconnect the electrical connector.
2 Rotate counterclockwise and remove the deactivator switch.
INSTALLATION
1. Pull the plunger out to its full travel. 2. Fully depress the brake pedal.
3. Install the deactivator switch.
1 Position the deactivator switch in the bracket and rotate clockwise.
2 Connect the electrical connector.
4. Slowly release the brake pedal. 5. Connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn its strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications
Cruise Control Servo: Specifications
Bracket to Speed Control Servo Screw
............................................................................................................................................. 8-11 N.m
(71-97 Lb-In) Speed Control Servo Nut ...............................................................................................
..................................................................... 5-7 N.m (45-62 Lb-In) Engine Cover Nut .......................
.......................................................................................................................................................
6-10 N.m (62-89 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8540
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8541
Cruise Control Servo: Service and Repair
REMOVAL
1. Remove the speed control actuator cable.
2. Disconnect the speed control servo electrical connector.
3. Remove the speed control servo and bracket.
1 Remove the bolts.
2 Remove the speed control servo and bracket.
4. Remove the speed control servo bracket.
1 Remove the screws.
2 Remove the speed control servo bracket.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8542
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications
Cruise Control Servo Cable: Specifications
Battery Ground Cable ..........................................................................................................................
............................................. 7-10 N.m (62-89 Lb-In) Engine Cover Nut .............................................
................................................................................................................................. 6-10 N.m (62-89
Lb-In) Speed Control Actuator Cable-to- Accelerator Cable Bracket Bolt
..........................................................................................................................................................
3-4 N.m (27-35 Lb-In)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page
8546
Cruise Control Servo Cable: Adjustments
1. Remove the retaining clip from the speed control actuator cable adjuster.
2. Pull on the speed control actuator cable to take up slack, then back off at least one notch so
there is approximately 3 mm (0.118 in) of slack in the
speed control actuator cable.
NOTE: Ensure the throttle is in the fully closed position.
3. Insert the speed control actuator cable retaining clip and snap into place. 4. Verify that the
throttle linkage operates freely and smoothly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page
8547
Cruise Control Servo Cable: Service and Repair
REMOVAL
1. Remove the engine cover.
1 Remove the nut.
2 Remove the engine cover.
2. Remove the speed control actuator cable from the throttle lever.
1 Remove the bolt.
2 Remove the speed control actuator cable from the throttle lever.
3. Remove the speed control actuator cable cap.
1 Depress the locking tab.
2 Remove the speed control actuator cable cap.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page
8548
4. Remove the speed control actuator cable from the speed control servo pulley.
1 Remove the speed control cable slug.
2 Remove the speed control actuator cable.
INSTALLATION
1. Insert the speed control cable slug into the speed control servo pulley slot.
2. Release the compressed spring while aligning the speed control actuator cable cap tabs with the
slots in the speed control servo housing.
NOTE: Ensure the rubber seal is fully seated onto the speed control actuator cable cap.
- Incorrect wrapping of the speed control actuator cable around the speed control servo pulley may
result in a high idle condition.
3. Rotate the speed control actuator cable cap until the locking tab engages.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page
8549
4. Connect the speed control actuator cable to the throttle lever.
1 Install the bolt.
2 Connect the speed control actuator cable to the throttle lever by snapping into place.
5. Adjust the speed control actuator cable.
6. Install the engine cover.
1 Position the engine cover.
2 Install the nut.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair
Cruise Control Switch: Service and Repair
REMOVAL
1. Remove the steering wheel.
2. Remove the steering wheel cover screws.
3. Remove the steering wheel cover.
1 Position the steering wheel cover aside.
2 Disconnect the electrical connector and wire harness from the steering wheel cover.
3 Remove the steering wheel cover.
4. Remove the speed control actuator switches.
1 Push the speed control actuator switches out towards the face of the steering wheel.
2 Position the speed control actuator switches through the steering wheel openings and remove.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch
(Cruise Control)] > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch
(Cruise Control)] > Component Information > Diagrams > Page 8557
Deactivator Switch: Adjustments
NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch
(Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch
Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the lower insulator.
1 Remove the push pins.
2 Disconnect the interior lamp.
3 Remove the lower insulator.
3. Disconnect the Brake Pedal Position (BPP) switch.
4. Remove the BPP switch.
1 Remove the cotter pin.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch
(Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8560
2 Remove the sleeve.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch
(Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 8561
Deactivator Switch: Service and Repair Deactivator Switch
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the deactivator switch.
1 Disconnect the electrical connector.
2 Rotate counterclockwise and remove the deactivator switch.
INSTALLATION
1. Pull the plunger out to its full travel. 2. Fully depress the brake pedal.
3. Install the deactivator switch.
1 Position the deactivator switch in the bracket and rotate clockwise.
2 Connect the electrical connector.
4. Slowly release the brake pedal. 5. Connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn its strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair
Cruise Control Switch: Service and Repair
REMOVAL
1. Remove the steering wheel.
2. Remove the steering wheel cover screws.
3. Remove the steering wheel cover.
1 Position the steering wheel cover aside.
2 Disconnect the electrical connector and wire harness from the steering wheel cover.
3 Remove the steering wheel cover.
4. Remove the speed control actuator switches.
1 Push the speed control actuator switches out towards the face of the steering wheel.
2 Position the speed control actuator switches through the steering wheel openings and remove.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Description and Operation
ABS Light: Description and Operation
The anti-lock brake warning indicator illuminates when the anti-lock brake control module detects a
fault in the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Description and Operation > Page 8569
ABS Light: Testing and Inspection
For testing procedures for this component, refer to Instrument Panel, Gauges and Warning
Indicators, Instrument Cluster, Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition
Switch - High Turning Effort/MIL ON/DTC's Set
Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set
Article No. 01-21-13
10/29/01
^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039
CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH
EFFORT WHEN TURNING IGNITION SWITCH
^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN
TURNING IGNITION SWITCH
FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001
EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002
SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER
SPORT TRAC
LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER
ISSUE
Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent
conditions:
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent
accessory function.
^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes
P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory.
This may be caused by a Key-In-Ignition warning chime switch.
ACTION
Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock
cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the battery ground cable and wait at least one minute.
2. Insent the ignition key and turn it to the RUN position.
3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock
cylinder) and press the release button while pulling out the ignition switch lock cylinder.
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD
REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH
LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS
REQUIRED.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition
Switch - High Turning Effort/MIL ON/DTC's Set > Page 8578
4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while
sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model
Workshop Manual, Key-in-ignition warning switch removal and installation section located in
Section 413 if additional detail is required.
5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder.
6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime
switch.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
012113A Replace The 0.3 Hr.
Key-In-Ignition Warning Chime Switch
DEALER CODING
CONDITION
BASIC PART NO. CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000,
208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct >
01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set
Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL
ON/DTC's Set
Article No. 01-21-13
10/29/01
^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039
CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH
EFFORT WHEN TURNING IGNITION SWITCH
^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN
TURNING IGNITION SWITCH
FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001
EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002
SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER
SPORT TRAC
LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER
ISSUE
Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent
conditions:
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent
accessory function.
^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes
P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory.
This may be caused by a Key-In-Ignition warning chime switch.
ACTION
Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock
cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the battery ground cable and wait at least one minute.
2. Insent the ignition key and turn it to the RUN position.
3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock
cylinder) and press the release button while pulling out the ignition switch lock cylinder.
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD
REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH
LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS
REQUIRED.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct >
01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 8584
4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while
sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model
Workshop Manual, Key-in-ignition warning switch removal and installation section located in
Section 413 if additional detail is required.
5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder.
6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime
switch.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
012113A Replace The 0.3 Hr.
Key-In-Ignition Warning Chime Switch
DEALER CODING
CONDITION
BASIC PART NO. CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000,
208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions
Audible Warning Device: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8587
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8588
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8589
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8590
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8591
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8592
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8593
Audible Warning Device: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8594
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8595
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8596
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8597
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8598
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8599
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8600
Audible Warning Device: Electrical Diagrams
Diagram 66-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8601
Diagram 66-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Description and Operation > Principles of Operation
Audible Warning Device: Description and Operation Principles of Operation
Chimes and tones are produced and managed by the Lighting Control Module (LCM). The LCM
provides sound for three different functions: reminder chimes, depression tones for the fuel
computer switches and the electronic crash sensor (ESC) warning chime.
The reminder chime alerts the driver to conditions that require attention, such as an unfastened
safety belt, the key in ignition when the driver door is open and headlamps or parklamps left on
with the ignition switch in the OFF position.
When the ignition switch is turned to RUN or START from OFF or ACC, the safety belt warning
chime will sound for six seconds or until the safety belt is buckled.
The safety belt warning indicator lamp will turn on for 60 seconds or until the driver seat belt is
buckled. Both the chime and lamp will turn on at the same time.
If the safety belt is buckled before the ignition switch is turned to RUN or START from OFF or ACC,
neither the chime nor the lamp will be activated.
The key-in-ignition warning chime will sound when the driver side door is opened with the key in
the ignition and the ignition switch is in the OFF or ACC position. It will continue to sound until the
key is removed, the front door is closed or the ignition switch is turned to RUN or START.
The headlamp-on reminder chime will be activated if the headlamps are on, the key is not in the
ignition and the driver door is opened.
The ECS warning chime will sound when a faulty ECS module is detected. The ESC module
requests a tone via a hard wired signal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Description and Operation > Principles of Operation > Page 8604
Audible Warning Device: Description and Operation Warning Devices
The warning device (chimes) system consists of the following components:
^ key-in-ignition warning switch
^ door ajar switch
^ Lighting Control Module (LCM)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Audible Warning Device: Initial Inspection and Diagnostic Overview
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical
damage.
VISUAL INSPECTION CHART
Mechanical ^
Door ajar switches
Electrical ^
Central Junction Box (CJB) Fuses 4 (15 A), 8 (15 A), 6 (15 A), 13 (15 A), circuit breaker 12 (18 A)
^ Circuitry
^ Damaged or corroded connectors
^ Lighting Control Module (LCM)
^ Electronic instrument cluster
^ Electronic Crash Sensor (ECS) module
3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath the
instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester
does not communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR
Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Pinpoint Tests/A: No
Communication With Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and perform self- test diagnostics for the LCM module.
6. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code (DTC)
Index to continue diagnostics. See: Diagnostic
Trouble Code Descriptions
7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8607
Audible Warning Device: Diagnostic Trouble Code Descriptions
Part 1 Of 3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8608
Part 2 Of 3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8609
Part 3 Of 3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8610
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8611
Audible Warning Device: Pinpoint Tests
Icons Used With Pinpoint Tests
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8612
A1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8613
A2 - A3
B: No Communication W/Module - Unable to Enter Self-Test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8614
B1 - B2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8615
B3 - B4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8616
B5
C: The Headlamp Reminder Chime Doesn't Operate Correctly
C1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8617
C2 - C4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8618
C5
D1 - D2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8619
D3 - D4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8620
E1 - E2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8621
E3 - E4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8622
F1 - F3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8623
F4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8624
G1 - G4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8625
G5 - G6
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8626
Audible Warning Device: Testing and Inspection
Initial Inspection and Diagnostic Overview
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical
damage.
VISUAL INSPECTION CHART
Mechanical ^
Door ajar switches
Electrical ^
Central Junction Box (CJB) Fuses 4 (15 A), 8 (15 A), 6 (15 A), 13 (15 A), circuit breaker 12 (18 A)
^ Circuitry
^ Damaged or corroded connectors
^ Lighting Control Module (LCM)
^ Electronic instrument cluster
^ Electronic Crash Sensor (ECS) module
3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath the
instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester
does not communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR
Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Pinpoint Tests/A: No
Communication With Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and perform self- test diagnostics for the LCM module.
6. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code (DTC)
Index to continue diagnostics. See: Diagnostic
Trouble Code Descriptions
7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Diagnostic Trouble Code Descriptions
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8627
Part 1 Of 3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8628
Part 2 Of 3
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8629
Part 3 Of 3
Icons Used With Pinpoint Tests
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8630
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8631
A1
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A2 - A3
B: No Communication W/Module - Unable to Enter Self-Test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8633
B1 - B2
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8634
B3 - B4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8635
B5
C: The Headlamp Reminder Chime Doesn't Operate Correctly
C1
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C2 - C4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8637
C5
D1 - D2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8638
D3 - D4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8639
E1 - E2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8640
E3 - E4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8641
F1 - F3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8642
F4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8643
G1 - G4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8644
G5 - G6
Principles of Operation
Chimes and tones are produced and managed by the Lighting Control Module (LCM). The LCM
provides sound for three different functions: reminder chimes, depression tones for the fuel
computer switches and the electronic crash sensor (ESC) warning chime.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8645
The reminder chime alerts the driver to conditions that require attention, such as an unfastened
safety belt, the key in ignition when the driver door is open and headlamps or parklamps left on
with the ignition switch in the OFF position.
When the ignition switch is turned to RUN or START from OFF or ACC, the safety belt warning
chime will sound for six seconds or until the safety belt is buckled.
The safety belt warning indicator lamp will turn on for 60 seconds or until the driver seat belt is
buckled. Both the chime and lamp will turn on at the same time.
If the safety belt is buckled before the ignition switch is turned to RUN or START from OFF or ACC,
neither the chime nor the lamp will be activated.
The key-in-ignition warning chime will sound when the driver side door is opened with the key in
the ignition and the ignition switch is in the OFF or ACC position. It will continue to sound until the
key is removed, the front door is closed or the ignition switch is turned to RUN or START.
The headlamp-on reminder chime will be activated if the headlamps are on, the key is not in the
ignition and the driver door is opened.
The ECS warning chime will sound when a faulty ECS module is detected. The ESC module
requests a tone via a hard wired signal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8646
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Testing and Inspection > Page 8647
Audible Warning Device: Service and Repair
REMOVAL
1. Remove the ignition lock cylinder.
1 Insert the key into the ignition key and turn to the RUN position.
2 Insert a punch in the access hole of the steering column and press the release tab while pulling
out the ignition switch lock cylinder.
2. Remove the key-in-ignition warning switch.
1 Release the clip.
2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure
^ Verify ignition lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Lighting Control Module
Audible Warning Device Control Module: Diagrams Lighting Control Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Lighting Control Module > Page 8652
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Lighting Control Module > Page 8653
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Description and Operation
Brake Warning Indicator: Description and Operation
The brake system warning indicator has a dual function. It illuminates when the parking brake is
applied or when a low brake fluid condition exists in the brake master cylinder reservoir. The brake
system warning indicator will illuminate when there is a pressure differential between the front and
rear brake hydraulic systems.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component
Information > Description and Operation
Charge Lamp/Indicator: Description and Operation
The charging system indicator illuminates whenever the generator output is insufficient to maintain
battery state of charge or if the generator output is too high. Under normal operation, the indicator
goes out after the engine is started and the charging system begins to operate.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8664
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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> Diagrams > Diagram Information and Instructions > Page 8665
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8666
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8667
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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> Diagrams > Diagram Information and Instructions > Page 8668
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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> Diagrams > Diagram Information and Instructions > Page 8669
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 8670
Cigarette Lighter: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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> Diagrams > Diagram Information and Instructions > Page 8671
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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> Diagrams > Diagram Information and Instructions > Page 8672
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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> Diagrams > Diagram Information and Instructions > Page 8673
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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> Diagrams > Diagram Information and Instructions > Page 8674
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> Diagrams > Diagram Information and Instructions > Page 8675
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> Diagrams > Diagram Information and Instructions > Page 8676
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> Diagrams > Diagram Information and Instructions > Page 8677
Diagram 44-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information >
Specifications
Clock: Specifications
Instrument Cluster Finish Panel Bolts 2-3 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions
Clock: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8683
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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> Diagram Information and Instructions > Page 8684
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8685
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8686
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8687
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8688
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8689
Clock: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8690
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8691
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8692
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8693
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8694
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8695
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8696
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Diagram Information and Instructions > Page 8697
Diagram 44-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Page 8698
Clock: Description and Operation
The electric clock is centrally located on the instrument panel and displays time in a 12 hour format.
The display illuminates with the ignition switch in ACC or RUN and dims when the headlamps are
on.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview
Clock: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical or electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged electric clock
Electrical ^
Blown fuse: Central Junction Box (CJB) Fuse 8 (15 A)
- (CJB) Fuse 6 (15 A)
^ Damaged wire(s)
^ Loose or corroded connections
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview > Page 8701
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview > Page 8702
Clock: Pinpoint Tests
Icons Used With Pinpoint Test
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview > Page 8703
A1 - A2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview > Page 8704
73 Digital Multimeter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Page 8705
Clock: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the RH instrument panel finish panel.
^ Disconnect the electrical connector.
3. Remove the electric clock.
1 Remove the screws.
2 Remove the electric clock.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Description and Operation
Compass: Description and Operation
The compass:
^ is incorporated into the inside rear view mirror.
^ has a two-character display in the upper RH side of the mirror, which indicates the direction in
which the vehicle is pointed (N, NE, E, SE, S, SW, W, NW).
^ uses an electronic compass sensor built into the inside rear view mirror.
^ has compass adjustment (calibration and zone variation) controlled by a COMP switch on the
mirror.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview
Compass: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the vehicle along roads of known direction to duplicate
the customer concern with the compass. 2. Visually inspect for obvious signs of mechanical or
electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Physical damage to mirror assembly
Electrical ^
Blown fuse: Central Junction Box (CJB) Fuse 5 (15 A)
^ Damaged wiring harness
^ Loose or corroded connectors
^ Damaged compass sensor (part of inside rear view mirror)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the fault is not visually evident, determine the symptom and
proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8711
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8712
Compass: Pinpoint Tests
Icons Used With Pinpoint Tests
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8713
A1 - A2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8714
B1 - B2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8715
B3 - B4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8716
73 Digital Multimeter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Calibration Adjustment
Compass: Adjustments Compass Calibration Adjustment
1. Press and hold the COMP button until C appears (six seconds). Release the COMP button.
NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or
structures. Switch off all non-essential electrical accessories (rear window defrost, heater, A/C,
map lamps and wipers) and make sure all doors are shut.
2. Drive the vehicle at less than 8 km/h (5 mph) a continuous circle until the display turns off. 3. If
the C message does not turn off within five circles, demagnetize the vehicle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Calibration Adjustment > Page 8719
Compass: Adjustments Compass Zone Adjustment
1. Refer to the compass calibration zone map to select the correct compass zone setting for your
geographical location.
2. With the compass display turned on, press and hold the COMP button (for three seconds) until
the display shows the current zone of operation. 3. Momentarily press the COMP button to cycle
the zone number display. Set the zone display number to match the vehicle location on the
compass
calibration zone map.
4. Releasing the switch for 10 seconds will exit the zone setting mode.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Calibration Adjustment > Page 8720
Compass: Adjustments Vehicle Demagnetizing
CAUTION: During demagnetizing, the demagnetizer Coil will be pulled toward the vehicle. Place a
cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth
covers the front third and the entire width of the roof.
NOTE
^ The demagnetizing process requires the use of a demagnetizing Coil commonly used by
television repair technicians to demagnetize television tubes.
^ To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the
demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained
in the vehicle.
^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite
the handle) is closest to the vehicle surface.
1. Demagnetize the front third of the vehicle roof.
1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle.
2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger
side, demagnetize the front third of the roof closest to the windshield using a constant circular
motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the
roof closest to the windshield. Continue the circular motion four times.
3 After the fourth pass and without stopping, move the demagnetizer at least away from the
vehicle.
4 Turn the demagnetizer off.
2. Demagnetize the inside rear view mirror mounting pad.
1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle.
2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside
rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft)
away from the vehicle.
3 Turn the demagnetizer off.
NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5
cm (1 in).
3. Perform the compass zone adjustment procedure. See: Compass Zone Adjustment 4. Perform
the calibration adjustment procedure. See: Compass Calibration Adjustment
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Page 8721
Compass: Service and Repair
NOTE: The compass display and module are integral to the inside rear view mirror and not
replaced separately.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8728
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) >
Component Information > Description and Operation
Fuel Gauge Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 8733
Fuel Gauge Module (CNG): Testing and Inspection
The Compressed Natural Gas fuel level indicator system is a function of the Natural Gas Vehicle
(NGV) module. For Testing and Inspection procedures,
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 8734
Fuel Gauge Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 8735
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module (CNG) >
Component Information > Description and Operation > Page 8736
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster /
Carrier] > Air Bag(s) Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster /
Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming
Deactivation Procedures
1. Disconnect the battery ground cable and wait at least one minute.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Remove
the passenger air bag module from the vehicle.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable.
Reactivation Procedures
1. Disconnect the battery ground cable.
WARNING: The air bag simulators must be removed and the air bag modules reconnected when
the system is reactivated to avoid non-deployment in a collision, resulting in possible personal
injury.
2. Wait at least one minute for the backup power supply in the air bag Electronic Crash Sensor
(ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle
harness connector at the top of the steering column. 4. Install the driver air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag
module. 6. Install the passenger air bag module.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
7. Reconnect the battery ground cable. 8. Prove out the system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster /
Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page
8743
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the air bag Electronic Crash Sensor (ECS) module connected? 4. Is the
vehicle battery connected?
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster /
Carrier] > Instrument Panel Bulb > Component Information > Service and Repair
Instrument Panel Bulb: Service and Repair
REMOVAL
1. Remove the instrument cluster.
2. Remove the warning indicator bulb.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Warning Switch <--> [Key Reminder
Switch] > Component Information > Service and Repair
Key Warning Switch: Service and Repair
REMOVAL
1. Remove the ignition lock cylinder.
1 Insert the key into the ignition key and turn to the RUN position.
2 Insert a punch in the access hole of the steering column and press the release tab while pulling
out the ignition switch lock cylinder.
2. Remove the key-in-ignition warning switch.
1 Release the clip.
2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure
^ Verify ignition lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Information > Description and Operation
Low Fuel Lamp/Indicator: Description and Operation
The low fuel warning indicator is controlled by the fuel indicator module and warns the driver when
the fuel level is one-eighth or lower in the tank.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
SERVICE ENGINE SOON
Your vehicle is equipped with a computer that monitors the engine's emission control system. This
is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the
environment by ensuring that your vehicle continues to meet government emission standards. The
OBD II system also assists the service technician in properly servicing your vehicle.
The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON
position to check the bulb. If it comes on after the engine is started, on of the engine's emission
control systems may be malfunctioning. The light may illuminate without a driveability concern
being noted. The vehicle will ususally be drivable and will not require towing.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation > Page 8756
Maintenance Required Lamp/Indicator: Service and Repair
Solid SERVICE ENGINE SOON light
This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary
malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or
water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened.
The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or
properly installing and securely tightening the gas cap. After three driving cycles with out these or
any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A
driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No
additional vehicle service is required.
Blinking SERVICE ENGINE SOON light
Engine misfire is occurring which could cause damage to your catalytic converter. You should drive
in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced
at the first available opportunity.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Description and Operation
Odometer: Description and Operation
The speedometer and odometer provides speed information based on a speed/distance pulse
signal from the Vehicle Speed Sensor (VSS). The VSS is mounted on the speedometer driven gear
in the transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED
indicator.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Oil Pressure Switch <--> [Oil
Pressure Sender] > Component Information > Locations
Engine Oil Pressure Switch: Locations
1. Oil Pressure Sensor
2. Oil Pressure Sensor Connector
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Oil Pressure Switch <--> [Oil
Pressure Sender] > Component Information > Locations > Page 8766
Engine Oil Pressure Switch: Service and Repair
Removal
1. Remove the oil pressure sensor oil pressure sensor:
1 Disconnect the wire.
2 Remove the oil pressure sensor.
Installation
1. Follow the removal procedure in reverse order.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator >
Component Information > Description and Operation
Oil Pressure Warning Lamp/Indicator: Description and Operation
The low oil pressure warning indicator illuminates when the oil pressure switch opens, indicating oil
pressure that is below the normal range.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component
Information > Description and Operation
Overdrive Indicator Lamp: Description and Operation
The overdrive off (O/D OFF) indicator has dual functions. The O/D OFF indicator illuminates when
the overdrive is turned off. The O/D OFF indicator also illuminates if a fault is detected in the
automatic transmission.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module
Audible Warning Device Control Module: Diagrams Lighting Control Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 8778
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Lighting Control Module > Page 8779
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module (CNG) > Component Information > Description and Operation
Fuel Gauge Module (CNG): Description and Operation
The NGV module assembly:
^ consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.
^ houses the unique electronics required for natural gas fuel systems.
^ is located on the center radiator support, behind the radiator grille.
The NGV module carries out the following functions:
^ injector drivers: the NGV module accepts eight unmodified injector signals from the Powertrain
Control Module (PCM) and allows a peak-and-sustain current to flow through the injector solenoids.
NOTE: No injector calculations are carried out; the injector driver output is not determined by the
NGV module.
^ fuel gauge driver: the NGV module uses fuel tank temperature and fuel tank pressure inputs to
calculate the density of the fuel; a look-up table is used to determine the output signal to the low
fuel warning switch (through a combination of discreet resistors), which drives the fuel gauge
located in the instrument cluster.
^ power and ground supply: the NGV module supplies power to the instrument cluster components
on Circuit 231 (BK/YE) when the ignition switch is in the RUN and START positions. Ground for the
fuel gauge, the low fuel level warning switch and the voltmeter is supplied on Circuit 570 (BK/WH).
Circuit 231 (BK/YE) also supplies power to the following components in the instrument cluster: low fuel indicator
- CHECK ENGINE indicator (Malfunction Indicator Lamp [MIL])
- speedometer
- temperature gauge
- oil pressure gauge
- Anti-lock Braking System (ABS) indicator
- overdrive (OD) OFF indicator
- brake warning indicator
- AIR BAG warning indicator
- fail-safe cooling indicator
Fuel Tank Pressure Sensor The fuel tank pressure sensor: ^
contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.
^ has an output that is linear from 0 kPa (0 psi) up to 27,579.03 kPa (4000 psi).
^ is located in the upper tank vent box on the upper tank rack.
Fuel Tank Temperature Sensors The fuel tank temperature sensors: ^
change resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).
^ provides a signal to the NGV module that indicates the temperature of the fuel
^ are located next to the fuel tanks, one in the vent box at Fuel Tank No.1 (Fuel Tank Temperature
Sensor No.1) and one below the vehicle at Fuel Tank No.4 (Fuel Tank Temperature Sensor No.2)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8783
Fuel Gauge Module (CNG): Testing and Inspection
The Compressed Natural Gas fuel level indicator system is a function of the Natural Gas Vehicle
(NGV) module. For Testing and Inspection procedures,
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8784
Fuel Gauge Module (CNG): Service and Repair
REMOVAL
WARNING
^ DO NOT MODIFY SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE
COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH NATURAL GAS.
FORD MOTOR COMPANY HAS SPECIALLY DESIGNED THE MATERIALS, COMPONENTS,
AND SYSTEM CONFIGURATION FOR THIS ENGINE, AND EACH PARTICULAR SYSTEM IS
PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS
OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT
IN FIRE, PERSONAL INJURY, OR CAUSE ENGINE DAMAGE.
^ IT IS IMPORTANT THAT YOUR NATURAL GAS VEHICLE BE CORRECTLY MAINTAINED BY
FORD NATURAL GAS TRAINED PERSONNEL. IF A PROBLEM OCCURS, IT IS IMPORTANT
THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF THE PROBLEM
RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO
KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. COMPRESSED NATURAL
GAS COMPONENTS AND STANDARD FUEL COMPONENTS ARE NOT INTERCHANGEABLE.
IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH NATURAL GAS FUELED
VEHICLE PROCEDURES, DAMAGE MAY OCCUR AND YOUR WARRANTY MAY BE
INVALIDATED.
1. Disconnect the battery ground cable.
2. Remove the upper radiator sight shield.
3. Remove the Natural Gas Vehicle (NGV) module harness connector cover.
4. Remove the NGV module electrical connector.
1 Loosen the NGV module electrical connector bolt.
2 Disconnect the NGV module electrical connector.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8785
5. Remove the NGV module and bracket assembly.
1 Remove the bolts.
2 Remove the NGV module and bracket assembly.
6. Remove the NGV module bracket assembly screws.
7. Remove the NGV module.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module (CNG) > Component Information > Description and Operation > Page 8786
1. To install, reverse the removal procedure.
^ Be sure to install the NGV module harness connector cover to prevent water from entering the
NGV module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fasten Belts Indicator <--> [Seat Belt
Reminder Lamp] > Component Information > Description and Operation
Fasten Belts Indicator: Description and Operation
The safety belt indicator is directly hardwired to the Lighting Control Module (LCM). The LCM
controls the safety belt indicator depending on the signal it receives from the safety belt buckle
switch. The safety belt indicator illuminates when the safety belt is not buckled, closing the safety
belt buckle switch.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Key Warning Switch <--> [Key Reminder Switch] > Component Information > Service and Repair
Key Warning Switch: Service and Repair
REMOVAL
1. Remove the ignition lock cylinder.
1 Insert the key into the ignition key and turn to the RUN position.
2 Insert a punch in the access hole of the steering column and press the release tab while pulling
out the ignition switch lock cylinder.
2. Remove the key-in-ignition warning switch.
1 Release the clip.
2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder.
INSTALLATION
1. To install, reverse the removal procedure
^ Verify ignition lock cylinder operation.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information >
Adjustments
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the transmission range
selector lever in the OD position.
^ Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate
two detents counterclockwise (OD position).
3. Hang a 1.36 Kg (3 lbs.) weight on the range selector lever.
4. Center the pointer in the middle of the OD position.
^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 1.36 Kg (3 lbs.) weight. 6. Carefully move the shift range selector lever from detent
to detent and compare with transmission settings.
^ Re-adjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Description and Operation
Speedometer Head: Description and Operation
The speedometer and odometer provides speed information based on a speed/distance pulse
signal from the Vehicle Speed Sensor (VSS). The VSS is mounted on the speedometer driven gear
in the transmission. The signal sent to the Speedometer / odometer is affected by various factors
and combinations such as:
- Tire size
- Gear ratio
- Number of teeth on the VSS driven gear
The allowable acceptable variations for indicated vehicle speed are:
Speedometer/Odometer Value Indicated
................................................................................................................................................
Allowable Range
48 km/h (30 mph) Actual Speed
......................................................................................................................................................
45-56 km/h (28-35 mph) 97 km/h (30 mph) Actual Speed
.....................................................................................................................................................
93-104 lm/h (58-65 mph) Odometer Measures Over Actual 16 km (10 Miles) Distance
................................................................................................. 15.4-16.6 km (9.6-10.3 miles)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Suspension Warning Indicator >
Component Information > Description and Operation
Suspension Warning Indicator: Description and Operation
The CHECK AIR SUSPENSION warning indicator illuminates when a concern in the air suspension
system is detected or when the air suspension switch is in the OFF position. During prove-out,
when a concern is detected or the air suspension switch is OFF, an audible tone will sound and the
CHECK AIR SUSPENSION warning indicator will flash on and off for five seconds. The CHECK
AIR SUSPENSION warning indicator will then remain illuminated until the concern is corrected or
the air suspension switch is switched ON.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Description and Operation
Temperature Gauge: Description and Operation
The engine coolant temperature gauge indicates the engine coolant temperature based on the
operating resistance range from the engine coolant temperature sender. If the engine coolant
temperature is low, the sender resistance is high. If the engine coolant temperature is high, the
sender resistance is low. The engine coolant temperature sender resistance range should be
between 9.7 ohms and 74 ohms.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Coolant Temperature Sender <-->
[Temperature Sensor (Gauge)] > Component Information > Service and Repair
Engine Coolant Temperature Sender: Service and Repair
Removal
CAUTION: Do not mix standard (green) coolant with Extended Life Coolant (orange).
1. Partially drain the engine cooling system.
2. Remove the water temperature indicator sender unit.
1 Disconnect the electrical connector.
2 Remove the water temperature indicator sender unit.
Installation
1. Install the water temperature indicator sender unit.
1 Install the water temperature indicator sender unit.
2 Connect the electrical connector.
2. Fill the engine cooling system.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp >
Component Information > Description and Operation
Traction Control Indicator Lamp: Description and Operation
The traction control indicator is located in the indicator lamp module and illuminates when the
traction control system is disabled.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 8816
Ambient Light Sensor: Service and Repair
REMOVAL
1. Unclip the instrument panel upper finish panel.
2. Disconnect the light sensor amplifier electrical connector.
CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel
to expose the connector without stretching the wiring.
3. Unclip the light sensor amplifier.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling
Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8829
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling
Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8835
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8838
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8839
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8840
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8841
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8842
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8843
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8844
Brake Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8845
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8846
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8847
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8848
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8849
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8850
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8851
Brake Lamp: Electrical Diagrams
Diagram 90-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8852
Diagram 90-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8853
Diagram 90-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 8854
Diagram 90-4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 8855
Brake Lamp: Description and Operation
PRINCIPLES OF OPERATION
NOTE: The stoplamps are powered from the Brake Pedal Position (BPP) switch directly, not from
the Lighting Control Module (LCM).
Stoplamps Stoplamps are mounted in the same housings as the rear lamp.
Stoplamp functions are carried out by double filament bulbs. The low power filaments are
dedicated to the parking lamp operation. Stoplamps utilize the high power filaments when the driver
applies the brake pedal, closing the BPP switch.
Power is routed from the BPP switch directly to the stoplamps.
High Mounted Stoplamp The high mounted stoplamp is mounted in the rear window area. It
operates in conjunction with the stoplamps.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis
Brake Lamp: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged Brake Pedal Position (BPP) switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 1(15 A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged stoplamp bulb(s)
^ Damaged BPP switch
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8858
Brake Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged Brake Pedal Position (BPP) switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 1(15 A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged stoplamp bulb(s)
^ Damaged BPP switch
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8859
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8860
Brake Lamp: Pinpoint Tests
Icons Used With Pinpoint Tests
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8861
K1 - K2
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8862
K3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8863
L1 - L2
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 8864
M1 - M2
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
8865
Brake Lamp: Service and Repair
REMOVAL
1. Remove the two high mounted stoplamp screws.
2. Remove the high mounted stoplamp assembly.
1 Disconnect the electrical connector.
2 Depress the clips and remove the high mounted stoplamp assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
8866
73 Digital Multimeter
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins
> Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins
> Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 8875
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Brake Light Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative >
Page 8881
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
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> Page 8882
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Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins
> Page 8883
Brake Light Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the LH instrument panel insulator. ^
Disconnect the courtesy lamp.
3. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
4. Remove the BPP switch.
1 Remove the self-locking pin.
2 Remove the (A) BPP switch from the (B) brake master cylinder push rod.
3 Remove the brake master cylinder push rod spacer.
4 Remove the brake master cylinder push rod bushing.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component
Information > Technical Service Bulletins > Customer Interest for High Mounted Stop Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling
High Mounted Stop Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component
Information > Technical Service Bulletins > Customer Interest for High Mounted Stop Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 8892
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stop Lamp: > 02-17-6 > Sep >
02 > A/T - Inadvertent Shift Interlock Disabling
High Mounted Stop Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stop Lamp: > 02-17-6 > Sep >
02 > A/T - Inadvertent Shift Interlock Disabling > Page 8898
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Cornering Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8903
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8904
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8905
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8906
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8907
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8908
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8909
Cornering Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8910
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8911
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8912
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8913
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8914
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8915
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8916
Diagram 91-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 8917
Cornering Lamp: Description and Operation
PRINCIPLES OF OPERATION
The cornering lamps are powered from the turn signal circuit. When the multifunction switch is
activated and the headlamps are on, the cornering lamp on the turn side will illuminate, and remain
illuminated until the turn signal cancels.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis
Cornering Lamp: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged multifunction switch
Electrical ^
Damaged wiring harness
^ Loose or corroded connection
^ Damaged bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern remains after the inspection, connect the New
Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle. check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See:
Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual
Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8920
Cornering Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged multifunction switch
Electrical ^
Damaged wiring harness
^ Loose or corroded connection
^ Damaged bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern remains after the inspection, connect the New
Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle. check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See:
Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual
Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8921
Cornering Lamp: Diagnostic Trouble Code Descriptions
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8922
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8923
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8924
Cornering Lamp: Testing and Inspection
Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged multifunction switch
Electrical ^
Damaged wiring harness
^ Loose or corroded connection
^ Damaged bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern remains after the inspection, connect the New
Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle. check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See:
Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual
Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged multifunction switch
Electrical ^
Damaged wiring harness
^ Loose or corroded connection
^ Damaged bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern remains after the inspection, connect the New
Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle. check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See:
Headlamp/Testing and Inspection/Component Tests and General Diagnostics/With Manual
Headlamps/Pinpoint Tests/A No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8925
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8926
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8927
Icons Used With Pinpoint Tests
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8928
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8929
N1 - N2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8930
O1 - O4
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Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8931
P1 - P2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8932
P3 - P4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8933
Q1
R1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8934
S1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8935
T1
U1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 8936
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection >
Page 8937
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Courtesy Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8942
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8943
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8944
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8945
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8946
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8947
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8948
Courtesy Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8949
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8950
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8951
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8952
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8953
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8954
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8955
Courtesy Lamp: Electrical Diagrams
Diagram 89-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8956
Diagram 89-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8957
Diagram 89-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 8958
Diagram 89-4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications
Daytime Running Lamp Control Unit: Specifications
Daytime Running Lamps Module Bolt 27 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications > Page 8963
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications > Page 8964
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Remove the battery ground cable.
2. Remove the sight shield.
^ Twist the clips.
3. Remove the Daytime Running Lamps (DRL) module
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the DRL module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging
Dome Lamp: Customer Interest Dome Lamp/Headliner - Sagging
Article No. 99-20-8
10/04/99
INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999
FORD: 1999-2000 CROWN VICTORIA
MERCURY: 1999-2000 GRAND MARQUIS
ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be
caused by the headliner material which was revised in the 1999 model to a less rigid material.
During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof
sheet metal prior to the adhesive curing.
ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof
sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an
adhesive attachment between the headliner and roof sheet metal. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
1. Remove the dome lamp lens.
2. Remove screws that secure the lamp assembly to the mounting bracket.
3. Disconnect the electrical connector to the lamp assembly.
4. Remove the black mounting bracket through the hole in the headliner.
5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty
knife to scrape off the adhesive.
6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The
adhesive should now be exposed.
7. Locate and align the new mounting bracket to the headliner opening.
NOTE
THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING.
8. Push the mounting bracket and headliner up against the roof.
NOTE:
SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE
BRACKET STAYS CORRECTLY LOCATED.
9. Connect electrical connector to the lamp assembly.
10. Locate the lamp assembly to the mounting bracket. Tighten screws.
11. Install dome lamp lens.
PART NUMBER PART NAME
F3MZ-5451 536-BA Bracket - Single Light
F5AZ-5451 536-BA Bracket - Dual Beam Light
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8973
OPERATION DESCRIPTION TIME
992008A Install New Headliner 0.3 Hr.
Bracket
DEALER CODING
CONDITION
BASIC PART NO. CODE
5451536 33
OASIS CODES: 105000, 107000, 201100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging
Dome Lamp: All Technical Service Bulletins Dome Lamp/Headliner - Sagging
Article No. 99-20-8
10/04/99
INTERIOR - HEADLINER SAGS - VEHICLES BUILT 12/1998 THROUGH 9/1999
FORD: 1999-2000 CROWN VICTORIA
MERCURY: 1999-2000 GRAND MARQUIS
ISSUE The interior dome lamp may not be adhered to the roof on some vehicles. This may be
caused by the headliner material which was revised in the 1999 model to a less rigid material.
During assembly in hot/humid conditions, the dome lamp may sag and lose contact with the roof
sheet metal prior to the adhesive curing.
ACTION Remove the interior dome lamp mounting bracket. Clean any residual adhesive from roof
sheet metal. Install new mounting bracket with two-sided foam tape. This should provide an
adhesive attachment between the headliner and roof sheet metal. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
1. Remove the dome lamp lens.
2. Remove screws that secure the lamp assembly to the mounting bracket.
3. Disconnect the electrical connector to the lamp assembly.
4. Remove the black mounting bracket through the hole in the headliner.
5. Clean any adhesive from the roof sheet metal above the opening in the headliner. Use a putty
knife to scrape off the adhesive.
6. Remove the plastic film from the foam tape on the back of the new mounting bracket. The
adhesive should now be exposed.
7. Locate and align the new mounting bracket to the headliner opening.
NOTE
THE TWO (2) LONG LOCATOR PINS ARE AT THE REAR SIDE OF THE OPENING.
8. Push the mounting bracket and headliner up against the roof.
NOTE:
SIMULTANEOUSLY PUSH THE MOUNTING BRACKET AND HEADLINER UP TO ENSURE THE
BRACKET STAYS CORRECTLY LOCATED.
9. Connect electrical connector to the lamp assembly.
10. Locate the lamp assembly to the mounting bracket. Tighten screws.
11. Install dome lamp lens.
PART NUMBER PART NAME
F3MZ-5451 536-BA Bracket - Single Light
F5AZ-5451 536-BA Bracket - Dual Beam Light
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Dome Lamp: > 99-20-8 > Oct > 99 > Dome Lamp/Headliner - Sagging > Page 8979
OPERATION DESCRIPTION TIME
992008A Install New Headliner 0.3 Hr.
Bracket
DEALER CODING
CONDITION
BASIC PART NO. CODE
5451536 33
OASIS CODES: 105000, 107000, 201100
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins >
Page 8980
Dome Lamp: Service and Repair
REMOVAL
1. Carefully release the dome lamp lens.
2. Remove the three screws.
3. Remove the dome/map lamp assembly.
^ Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service
Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: Customer Interest Turn Signals - Intermittent Rapid Flashing
Article No. 02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY
FORD: 1998-2002 CROWN VICTORIA
MERCURY: 1998-2002 GRAND MARQUIS
This article is being republished in its entirety to update the Service Procedure and to update the
parts required.
ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the
turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn
signal fast flash is not due to bulb outage, then verify good continuity at all ground screws.
ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the
latest engineering level as follows:
1 Disconnect the battery ground cable. For additional information refer to Workshop Manual
Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year.
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and
shaft. For additional information, refer to Section 310-02 of the Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service
Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing
> Page 8989
4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).
5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service
Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing
> Page 8990
13C788 42
OASIS CODES: 201000, 201100, 201200, 206000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent
Rapid Flashing
Exterior Lighting Module: All Technical Service Bulletins Turn Signals - Intermittent Rapid Flashing
Article No. 02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY
FORD: 1998-2002 CROWN VICTORIA
MERCURY: 1998-2002 GRAND MARQUIS
This article is being republished in its entirety to update the Service Procedure and to update the
parts required.
ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the
turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn
signal fast flash is not due to bulb outage, then verify good continuity at all ground screws.
ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the
latest engineering level as follows:
1 Disconnect the battery ground cable. For additional information refer to Workshop Manual
Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year.
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and
shaft. For additional information, refer to Section 310-02 of the Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent
Rapid Flashing > Page 8996
4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).
5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent
Rapid Flashing > Page 8997
13C788 42
OASIS CODES: 201000, 201100, 201200, 206000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Police Option Emergency Flasher Relay #1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Police Option Emergency Flasher Relay #1 > Page 9003
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Hazard Flasher
Hazard Warning Flasher: Locations Hazard Flasher
Instrument Panel View
1996 Crown Victoria shown, others similar
The Hazard Flasher output is provided by the Lighting Control Module, which is located behind LH
side of the instrument panel. There are no separate relays for Hazard Flasher output aside from the
LCM.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Hazard Flasher > Page 9008
Hazard Warning Flasher: Locations Police Option Only
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Hazard Flasher > Page 9009
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Indicator > Component
Information > Description and Operation
Hazard Warning Indicator: Description and Operation
The LH and/or RH turn indicators will flash when the multifunction switch is placed in the RH or LH
turn signal ON position or when the hazard switch is placed in the ON position and the ignition is
ON. If the hazard switch is on and the ignition is OFF, only the hazard indicator in the indicator
lamp module will flash.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams
Hazard Warning Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 9016
Hazard Warning Switch: Description and Operation
PRINCIPLES OF OPERATION
The hazard flasher switch (part of the multifunction switch) is located on the top of the steering
column, forward of the steering wheel. ^
The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the
switch top.
^ The switch should produce an audible click when it toggles from one state to another.
^ The switch should extend markedly further above the column when the switch is ON than it does
when it is OFF.
When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the
two turn indicators in the instrument cluster will flash simultaneously.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Component Test
Hazard Warning Switch: Testing and Inspection Component Test
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Component Test > Page 9019
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Component Test > Page 9020
Hazard Warning Switch: Testing and Inspection Operational Test
The hazard flasher switch (part of the multifunction switch) is located on the top of the steering
column, forward of the steering wheel.
- The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the
switch top.
- The switch should produce an audible click when it toggles from one state to another.
- The switch should extend markedly further above the column when the switch is ON than it does
when it is OFF.
When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the
two turn indicators in the instrument cluster will flash simultaneously.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Page 9021
Hazard Warning Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Page 9022
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Page 9023
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications
Headlamp Bulb: Specifications
Low Beam 4.30 A 55 W
High Beam 5.08 A 65 W
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications >
Page 9028
Headlamp Bulb: Service and Repair
REMOVAL
WARNING: THE HALOGEN 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.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a
replacement 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 the headlamps on with the bulb removed.
1. Remove the headlamp assembly.
2. Rotate the headlamp bulb retainer counterclockwise and remove.
- Grasp the headlamp bulb by its base and remove the bulb.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE HALOGEN 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.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams
Headlamp Dimmer Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 9032
Headlamp Dimmer Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 9033
Headlamp Dimmer Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 9034
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 9035
Headlamp Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 9036
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 9037
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component
Information > Diagrams
Main Light Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Page 9041
Main Light Switch: Description and Operation
The headlamp switch is a multi-position switch.
^ The positions include OFF, PARK, and HEAD.
^ With the headlamp switch in the PARK position (first detent), a signal is supplied to the LCM
which powers the front parking lamps, the tail lamps, the side marker lamps, and the license lamp.
^ With the headlamp switch in the HEAD position, power is supplied to the headlamps through the
LCM and the multifunction switch.
^ The panel dim switch (part of the headlamp switch) is located above the headlamp switch. The
panel dim switch operates only with the parking lamps or headlamps on.
^ When the panel dim switch is held in the up position, the instrument panel lighting will
progressively brighten.
^ When the panel dim switch is held in the down position, the instrument panel lighting will
progressively dim.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Page 9042
Main Light Switch: Testing and Inspection
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Page 9043
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Page 9044
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component
Information > Diagrams > Page 9045
Main Light Switch: Service and Repair
REMOVAL
1. Remove the instrument panel cluster finish panel.
2. Remove the headlamp switch.
^ Unclip the switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Hi-Beam Indicator <--> [Hi-Beam Indicator Lamp] > Component Information
> Description and Operation
Hi-Beam Indicator: Description and Operation
The high beam indicator will illuminate when the multifunction switch is placed in the high beam
headlamps ON position or the flash-to-pass position.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9053
Horn Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9054
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair
Horn Switch: Service and Repair
REMOVAL AND INSTALLATION
NOTE: The horn switch is integral to the driver side air bag module and cannot be replaced
separately.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9062
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9063
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9064
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9065
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9066
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9067
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9068
Interior Lighting Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9069
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9070
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9071
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9072
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9073
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9074
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9075
Interior Lighting Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9076
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9077
Interior Lighting Module: Electrical Diagrams
Diagram 58-1
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Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9078
Diagram 58-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9079
Diagram 58-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions
Lamp Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9084
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9085
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9086
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9087
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9088
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9089
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9090
Lamp Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9091
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9092
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9093
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9094
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9095
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9096
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9097
Lamp Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9098
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9099
Lamp Control Module: Electrical Diagrams
Diagram 58-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9100
Diagram 58-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 9101
Diagram 58-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9102
Lamp Control Module: Description and Operation
The Lighting Control Module (LCM) eliminates the electronic interference and heat associated with
the thermoelectric devices used previously. The LCM is a microprocessor based module that
controls several vehicle subsystems. It responds to electrical signals from various switches,
sensors, and external modules.
LCM subsystem function include:
^ headlamps with autolamps
^ turn signal lamps/hazard flasher lamps
^ cornering lamps
^ parking lamps
^ courtesy lamps
^ demand lamps
^ battery saver
^ backlighting
^ interfacing with the driver door module via SCP for illuminated entry.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9103
Lamp Control Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the LH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Disconnect the courtesy lamp.
3 Remove the LH instrument panel insulator.
3. Position the LCM aside.
1 Remove the locking tab.
2 Release the locking tab.
3 Position the LCM aside.
4. Remove the LCM.
1 Disconnect the electrical connectors.
2 Remove the LCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Diagrams > Page 9104
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from New Generation STAR (NGS) Tester into the new module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions
License Plate Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9109
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9110
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9111
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9112
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9113
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9114
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9115
License Plate Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9116
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9117
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9118
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9119
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9120
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9121
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9122
License Plate Lamp: Electrical Diagrams
Diagram 92-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9123
Diagram 92-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9124
Diagram 92-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9125
Diagram 92-4
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Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9126
License Plate Lamp: Description and Operation
PRINCIPLES OF OPERATION
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection >
Flow of Diagnosis
License Plate Lamp: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15 A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection >
Flow of Diagnosis > Page 9129
License Plate Lamp: Initial Inspection and Diagnostic Overview
Inspection and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15 A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The license lamps have replaceable miniature bulbs and are provided power through the Lighting
Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or
AUTOLAMP positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection >
Flow of Diagnosis > Page 9130
License Plate Lamp: Diagnostic Trouble Code Descriptions
LCM Diagnostic Trouble Code Index
Part 1 Of 3
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License Plate Lamp: Testing and Inspection
Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15 A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Inspection and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15 A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
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7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The license lamps have replaceable miniature bulbs and are provided power through the Lighting
Control Module (LCM) and interconnected wiring with the headlamp switch in the PARK, HEAD, or
AUTOLAMP positions.
LCM Diagnostic Trouble Code Index
Part 1 Of 3
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Part 3 Of 3
Icons Used With Pinpoint Tests
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Flow of Diagnosis > Page 9138
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
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V1 - V3
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V4
W1
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W2 - W4
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X1 - X3
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Y1
Special Tools
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Page 9145
License Plate Lamp: Tools and Equipment
Special Tools Used While Performing Tests
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
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and Instructions > Page 9154
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Marker Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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and Instructions > Page 9161
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and Instructions > Page 9162
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Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9163
Marker Lamp: Electrical Diagrams
Diagram 92-1
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and Instructions > Page 9164
Diagram 92-2
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Diagram 92-3
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and Instructions > Page 9166
Diagram 92-4
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Marker Lamp: Description and Operation
PRINCIPLES OF OPERATION
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis
Marker Lamp: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
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Marker Lamp: Initial Inspection and Diagnostic Overview
Inspection and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Diagnosis > Page 9171
Marker Lamp: Diagnostic Trouble Code Descriptions
LCM Diagnostic Trouble Code Index
Part 1 Of 3
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Part 3 Of 3
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Marker Lamp: Testing and Inspection
Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Inspection and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
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7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
LCM Diagnostic Trouble Code Index
Part 1 Of 3
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Diagnosis > Page 9180
Part 3 Of 3
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Diagnosis > Page 9181
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Diagnosis > Page 9182
Icons Used With Pinpoint Tests
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Diagnosis > Page 9183
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Diagnosis > Page 9184
V1 - V3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9185
V4
W1
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Diagnosis > Page 9186
W2 - W4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9187
X1 - X3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9188
Y1
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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9189
Marker Lamp: Service and Repair
REMOVAL
1. Remove the sight shield.
^ Twist the clips.
2. Remove the screw.
3. From inside the engine compartment, remove the nut.
Grand Marquis shown, Crown Victoria Similar
4. Remove the side marker lamp assembly.
^ Disconnect the electrical connector(s).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Page
9190
^ If necessary, install new bulb(s).
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Parking Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9195
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9196
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9197
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9198
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9199
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9200
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9201
Parking Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Information and Instructions > Page 9205
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Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9206
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Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9207
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9208
Parking Lamp: Electrical Diagrams
Diagram 92-1
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Information and Instructions > Page 9209
Diagram 92-2
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Information and Instructions > Page 9210
Diagram 92-3
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Information and Instructions > Page 9211
Diagram 92-4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 9212
Parking Lamp: Description and Operation
PRINCIPLES OF OPERATION
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis
Parking Lamp: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9215
Parking Lamp: Initial Inspection and Diagnostic Overview
Principles of Operation (How Does It Work?)
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Inspections and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9216
Parking Lamp: Diagnostic Trouble Code Descriptions
LCM Diagnostic Trouble Code (DTC) Index
Part 1 Of 3
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Diagnosis > Page 9217
Part 2 Of 3
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Diagnosis > Page 9218
Part 3 Of 3
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Diagnosis > Page 9219
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Diagnosis > Page 9220
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Diagnosis > Page 9221
Parking Lamp: Testing and Inspection
Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Inspections and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
LCM Diagnostic Trouble Code (DTC) Index
Part 1 Of 3
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Diagnosis > Page 9223
Part 2 Of 3
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Diagnosis > Page 9224
Part 3 Of 3
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Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9225
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9226
Icons Used With Pinpoint Tests
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9227
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9228
V1 - V3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9229
V4
W1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9230
W2 - W4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9231
X1 - X3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9232
Y1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications
Daytime Running Lamp Control Unit: Specifications
Daytime Running Lamps Module Bolt 27 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 9237
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 9238
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Remove the battery ground cable.
2. Remove the sight shield.
^ Twist the clips.
3. Remove the Daytime Running Lamps (DRL) module
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the DRL module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to learn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02
> Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: Customer Interest Turn Signals - Intermittent Rapid Flashing
Article No. 02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY
FORD: 1998-2002 CROWN VICTORIA
MERCURY: 1998-2002 GRAND MARQUIS
This article is being republished in its entirety to update the Service Procedure and to update the
parts required.
ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the
turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn
signal fast flash is not due to bulb outage, then verify good continuity at all ground screws.
ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the
latest engineering level as follows:
1 Disconnect the battery ground cable. For additional information refer to Workshop Manual
Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year.
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and
shaft. For additional information, refer to Section 310-02 of the Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02
> Turn Signals - Intermittent Rapid Flashing > Page 9247
4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).
5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02
> Turn Signals - Intermittent Rapid Flashing > Page 9248
13C788 42
OASIS CODES: 201000, 201100, 201200, 206000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7
> May > 02 > Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: All Technical Service Bulletins Turn Signals - Intermittent Rapid Flashing
Article No. 02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS VEHICLES PRODUCED BEFORE 3/5/2002 ONLY
FORD: 1998-2002 CROWN VICTORIA
MERCURY: 1998-2002 GRAND MARQUIS
This article is being republished in its entirety to update the Service Procedure and to update the
parts required.
ISSUE Some vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the
turn signals. This may be caused by bulb outage, circuit ground or circuit integrity. Ensure the turn
signal fast flash is not due to bulb outage, then verify good continuity at all ground screws.
ACTION If condition is not resolved, replace the Lighting Control Module with the latest level part.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the
latest engineering level as follows:
1 Disconnect the battery ground cable. For additional information refer to Workshop Manual
Section 14-01 for 1998 model year; 414-01 for 1999-2002 model year.
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3. If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and
shaft. For additional information, refer to Section 310-02 of the Workshop Manual.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7
> May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9254
4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).
5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7
> May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9255
13C788 42
OASIS CODES: 201000, 201100, 201200, 206000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Police Option Emergency Flasher Relay #1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 9260
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 9264
Horn Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 9265
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9270
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9271
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9272
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9273
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9274
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9275
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9276
Interior Lighting Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9277
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9278
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9279
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9280
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9281
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9282
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9283
Interior Lighting Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9284
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9285
Interior Lighting Module: Electrical Diagrams
Diagram 58-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9286
Diagram 58-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9287
Diagram 58-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Lamp Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9292
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9293
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9294
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9295
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9296
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9297
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9298
Lamp Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Component Information > Diagrams > Diagram Information and Instructions > Page 9299
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9300
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9301
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9302
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9303
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9304
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9305
Lamp Control Module: Connector Views
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9306
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9307
Lamp Control Module: Electrical Diagrams
Diagram 58-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9308
Diagram 58-2
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 9309
Diagram 58-3
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Page 9310
Lamp Control Module: Description and Operation
The Lighting Control Module (LCM) eliminates the electronic interference and heat associated with
the thermoelectric devices used previously. The LCM is a microprocessor based module that
controls several vehicle subsystems. It responds to electrical signals from various switches,
sensors, and external modules.
LCM subsystem function include:
^ headlamps with autolamps
^ turn signal lamps/hazard flasher lamps
^ cornering lamps
^ parking lamps
^ courtesy lamps
^ demand lamps
^ battery saver
^ backlighting
^ interfacing with the driver door module via SCP for illuminated entry.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Page 9311
Lamp Control Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the LH instrument panel lower insulator.
1 Remove the pin-type retainers.
2 Disconnect the courtesy lamp.
3 Remove the LH instrument panel insulator.
3. Position the LCM aside.
1 Remove the locking tab.
2 Release the locking tab.
3 Position the LCM aside.
4. Remove the LCM.
1 Disconnect the electrical connectors.
2 Remove the LCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module >
Component Information > Diagrams > Page 9312
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from New Generation STAR (NGS) Tester into the new module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns it adaptive strategy. The vehicle may need to be drive 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Diagrams > Page 9317
Ambient Light Sensor: Service and Repair
REMOVAL
1. Unclip the instrument panel upper finish panel.
2. Disconnect the light sensor amplifier electrical connector.
CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel
to expose the connector without stretching the wiring.
3. Unclip the light sensor amplifier.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 >
Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 02-13-6 > Jul > 02 >
Stoplamps/Shift Interlock - Inoperative > Page 9329
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 02-13-6 >
Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Technical Service Bulletin # 02-13-6 Date: 020708
Stoplamps/Shift Interlock - Inoperative
Article No. 02-13-6
07/08/02
^ BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL
POSITION SWITCH WIRING CONNECTOR
^ ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT
FOR BRAKE PEDAL POSITION SWITCH WIRING CONNECTOR
FORD: 1998-2002 CROWN VICTORIA
LINCOLN: 1998-2002 TOWN CAR
MERCURY: 1998-2002 GRAND MARQUIS
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move
the shift lever from the Park position. Stop Lamp operation may also be aftected. This may be
caused by a deformed Brake Pedal Position Switch electrical connector.
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and
pigtail.
Refer to the following Service procedure for details.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021306A Replace Brake Pedal 0.4 Hr.
Position Switch Electrical Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 02-13-6 >
Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9335
3. Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278)
for deformation. Refer to Wiring Diagrams, Section 90 for additional details.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal
diagnostic information.
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD
light green with red strip with LG/RD).
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat
shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
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Component Information > Technical Service Bulletins > Page 9336
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Page 9337
Brake Light Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove LH instrument panel insulator.
1 Remove the pin-type retainers.
2 Remove the LH instrument panel insulator. ^
Disconnect the courtesy lamp.
3. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
4. Remove the BPP switch.
1 Remove the self-locking pin.
2 Remove the (A) BPP switch from the (B) brake master cylinder push rod.
3 Remove the brake master cylinder push rod spacer.
4 Remove the brake master cylinder push rod bushing.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Hazard Warning Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 9341
Hazard Warning Switch: Description and Operation
PRINCIPLES OF OPERATION
The hazard flasher switch (part of the multifunction switch) is located on the top of the steering
column, forward of the steering wheel. ^
The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the
switch top.
^ The switch should produce an audible click when it toggles from one state to another.
^ The switch should extend markedly further above the column when the switch is ON than it does
when it is OFF.
When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the
two turn indicators in the instrument cluster will flash simultaneously.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Component Test
Hazard Warning Switch: Testing and Inspection Component Test
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Component Test > Page 9344
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Component Test > Page 9345
Hazard Warning Switch: Testing and Inspection Operational Test
The hazard flasher switch (part of the multifunction switch) is located on the top of the steering
column, forward of the steering wheel.
- The hazard flasher switch should cycle smoothly from OFF to ON by pressing and releasing the
switch top.
- The switch should produce an audible click when it toggles from one state to another.
- The switch should extend markedly further above the column when the switch is ON than it does
when it is OFF.
When the hazard flasher switch is in the ON position, the four turn signal lamps will flash. Also, the
two turn indicators in the instrument cluster will flash simultaneously.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 9346
Hazard Warning Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 9347
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 9348
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams
Headlamp Dimmer Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 9352
Headlamp Dimmer Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 9353
Headlamp Dimmer Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 9354
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 9355
Headlamp Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 9356
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 9357
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams
Main Light Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 9361
Main Light Switch: Description and Operation
The headlamp switch is a multi-position switch.
^ The positions include OFF, PARK, and HEAD.
^ With the headlamp switch in the PARK position (first detent), a signal is supplied to the LCM
which powers the front parking lamps, the tail lamps, the side marker lamps, and the license lamp.
^ With the headlamp switch in the HEAD position, power is supplied to the headlamps through the
LCM and the multifunction switch.
^ The panel dim switch (part of the headlamp switch) is located above the headlamp switch. The
panel dim switch operates only with the parking lamps or headlamps on.
^ When the panel dim switch is held in the up position, the instrument panel lighting will
progressively brighten.
^ When the panel dim switch is held in the down position, the instrument panel lighting will
progressively dim.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 9362
Main Light Switch: Testing and Inspection
Component Testing Procedure
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 9363
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 9364
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <-->
[Headlamp Switch] > Component Information > Diagrams > Page 9365
Main Light Switch: Service and Repair
REMOVAL
1. Remove the instrument panel cluster finish panel.
2. Remove the headlamp switch.
^ Unclip the switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Service and Repair
Horn Switch: Service and Repair
REMOVAL AND INSTALLATION
NOTE: The horn switch is integral to the driver side air bag module and cannot be replaced
separately.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams
Multifunction Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 9372
Multifunction Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 9373
Multifunction Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 9374
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 9375
Multifunction Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 9376
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <-->
[Turn Signal Switch] > Component Information > Diagrams > Page 9377
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch >
Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement
Part
Article No. 01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES
1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION
LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD
MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree
Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical
switches will be available as a service replacement.
ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury
switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate
model year Workshop Manual as needed.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 201000, 201200
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications
Tail Lamp: Specifications
Rear Lamp Nuts 18 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9387
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9388
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9389
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9390
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9391
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9392
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9393
Tail Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9394
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9395
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9396
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9397
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9398
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9399
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9400
Tail Lamp: Electrical Diagrams
Diagram 92-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9401
Diagram 92-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9402
Diagram 92-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9403
Diagram 92-4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 9404
Tail Lamp: Description and Operation
PRINCIPLES OF OPERATION
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis
Tail Lamp: Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9407
Tail Lamp: Initial Inspection and Diagnostic Overview
Inspection and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9408
Tail Lamp: Diagnostic Trouble Code Descriptions
LCM Diagnostic Trouble Code Index
Part 1 Of 3
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Diagnosis > Page 9409
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9410
Part 3 Of 3
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Diagnosis > Page 9411
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9412
Tail Lamp: Testing and Inspection
Flow of Diagnosis
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Inspection and Verification (Start Testing Here)
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
Mechanical ^
Headlamp switch
Electrical ^
Blown Central Junction Box (CJB) Fuse 4 (15A)
^ Damaged wiring harness
^ Loose or corroded connection
^ Damaged parking, rear or license bulb(s)
^ Damaged Lighting Control Module (LCM)
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required. 4. If
the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the
Data Link Connector (DLC) located beneath
the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not
communicate with the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position.
5. If the NGS still does not communicate with the vehicle, refer to the NGS Tester manual. 6. Carry
out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
^ CKT914, CKT915 or CKT7O = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus.
^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Headlamp/Testing and
Inspection/Component Tests and General Diagnostics/With Manual Headlamps/Pinpoint Tests/A
No Communication With the Lighting Control Module
^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the LCM.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9413
7. If the DTCs retrieved are related to the concern, go to the LCM Diagnostic Trouble Code Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions/LCM Diagnostic Trouble Code Index
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue
diagnostics. See: Symptom Related Diagnostic Procedures
Principles of Operation (How Does It Work?)
The power to these lamps is provided through the Lighting Control Module (LCM) and
interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTO-LAMPS positions.
LCM Diagnostic Trouble Code Index
Part 1 Of 3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9414
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9415
Part 3 Of 3
Icons Used With Pinpoint Tests
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9416
Pinpoint Test Step Icons Chart
In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The
icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are
shown in the Pinpoint Test Step Icons chart.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9417
V1 - V3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9418
V4
W1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9419
W2 - W4
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9420
X1 - X3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9421
Y1
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 9422
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Page 9423
Tail Lamp: Service and Repair
REMOVAL
1. Position the luggage compartment trim aside.
^ Remove the pin-type retainer.
2. Remove the rear lamp nuts.
3. Remove the rear lamp assembly and disconnect the electrical connectors.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
Turn Signal Flasher: Locations
Instrument Panel View
1996 Crown Victoria shown, others similar
The Turn Signal Flasher output is provided by the Lighting Control Module, which is located behind
the LH side of the instrument panel. There are no separate relays for Turn Signal Flasher output
aside from the LCM.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information >
Description and Operation
Turn Signal Indicator: Description and Operation
The LH and/or RH turn indicators will flash when the multifunction switch is placed in the RH or LH
turn signal ON position or when the hazard switch is placed in the ON position and the ignition is
ON. If the hazard switch is on and the ignition is OFF, only the hazard indicator in the indicator
lamp module will flash.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams
Multifunction Switch: Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams > Page 9434
Multifunction Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams > Page 9435
Multifunction Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams > Page 9436
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams > Page 9437
Multifunction Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams > Page 9438
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component
Information > Diagrams > Page 9439
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement
Part
Article No. 01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES
1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION
LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD
MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree
Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical
switches will be available as a service replacement.
ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury
switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate
model year Workshop Manual as needed.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 201000, 201200
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 9450
Heated Glass Element Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 9451
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
TSB 04-24-5
12/13/04
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR
FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria,
Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005
Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape
2004-2005 F-150, Freestar 2005 Escape Hybrid
LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator
2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego
1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 04-18-9 to update vehicle applications and service procedure.
ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid
lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the
rear window glass.
ACTION Follow the diagnostic and repair procedures included in this article to inspect and service
rear defroster grid lines, integral antenna concerns or broken terminal tabs.
SERVICE PROCEDURE
Warrantable/Non Warrantable repairs
Warrantable grid line repairs typically can be identified by one inoperative grid line with a small
discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are
scratched or have the silver material removed are not warrantable and should be addressed with
the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable
repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated
Back Lite Damageability Job Aid for additional information and examples of defects and damage.
NOTE
THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE
GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY
APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9459
THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS
EXPLAINED IN THIS ARTICLE.
Examples Of Non-Warrantable Grid Line Damage
^ Ice scraper damage to grid lines
^ Animal scratches on grid lines
^ Window tint film/removal of the film which damages grid lines
^ Stickers placed over grids which upon removal, removes the grid line material
^ License plate (steel type placed against the inside of back glass) which rubs on the grid line
causing damage
^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal
removes grid line material
^ Cargo or lumber rubbing against the glass which removes grid line material
^ Cellular phone antenna installation/removal which damages grid line material
NOTE
AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE
SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL
ACROSS THEM.
GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL
IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON
THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR
12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID
LINE INOPERATIVE - DIAGNOSTICS
1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power
and ground to the back-glass.
2. Connect a test lamp or DVOM to a good body ground.
3. Turn the ignition key to the run position and depress and release the rear defroster button to turn
the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME
THE DEFROSTER BUTTON IS PRESSED.
4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM +
lead to each grid line. (Use caution not to damage grid lines). The DVOM should read
approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test
light, the bulb should be approximately the same brightness on each line from top to bottom. If the
DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid
line with the + test lead or test lamp until the voltage changes suddenly. This is the area of
concern, use chalk to mark the area of concern and mark the outside of the glass at that same
area.
5. Repair per the Grid Line Repair Procedure.
GRID LINE REPAIR PROCEDURE
NOTE
LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE,
HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS
TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE
(5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING
DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER
THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND
EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT
VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID
LINE AREAS.
NOTE
IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY
RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT
FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND
SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW
DEFROSTER REPAIR COMPOUND.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9460
Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or
equivalent meeting Ford specification ESB-M4J58-A as follows:
Surface Preparation
1. Bring vehicle inside and warm it to 60° F (16° C) or above.
2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of
the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service
area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry.
NOTE
THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE
PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME.
Mixing
The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at
room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake
frequently during use.
Application
1. Mark location of open grid on the outside of the back window glass (performed in diagnostics).
Place protective covering over the package tray as necessary.
2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is
best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should
be at the center of the mask and tape gap must be no wider than the existing grid line. Other types
of tape may be used but end results of the repair may not appear as visually acceptable due to
ease of application and tape edge finish.
3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound
to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five
(5) minutes drying time between coats) across the open grid line area using the brush applicator in
the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area.
Apply a minimum of six (6) coats of the grid repair compound.
4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown
lacquer touch-up paint across the open line area first. Take care to paint only the area missing the
color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at
least five (5) minutes between coats. Apply six (6) coats of grid repair compound.
NOTE
THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER
TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE
REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9461
TIME TO MATCH THE REST OF THE GRID.
5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step
outside and inspect the repaired area. If the repair compound is visible above or below the grid, the
excess can be removed. This may be done by placing a single-edge razor blade on the back
window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better
but may not be cosmetically appealing.
CAUTION
BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID
LINES FUNCTION PROPERLY WHEN FINISHED.
Curing
The service coating will air-dry in approximately one (1) minute and the system can be energized
after five minutes. Maximum hardness and adhesion occur after approximately 24 hours.
SOLDER METHOD OF LEAD TERMINAL
NOTE
THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE.
PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY.
The new terminal will cover the original terminal location, but must be placed so that the new
terminal conductive areas will be placed on a good conductive base. This area should be cleaned
with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be
cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous
polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to
improve appearance.
CAUTION
DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS
PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE
EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY
AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER.
BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN
CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT
TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL.
The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a
visual indication when the terminal has reached the proper temperature to melt the solder on the
terminal. When the proper temperature is achieved the temperature paint will liquefy and change
color.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9462
Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus,
use type B (Figure 3).
NOTE
DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS
COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL.
SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL
ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR
MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE
ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE
BUSS-BAR ON GOOD CONDUCTIVE MATERIAL.
1. Place the replacement terminal over the original tab location making sure the conductive areas
of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original
location which does not have conductive material (figure 4).
2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the
terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle
may allow the terminal to slip when the solder liquefies).
3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab.
Energize the soldering gun and watch for the painted area of the terminal to liquefy and change
color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint
color completely changes on either side of the terminal, de-energize the soldering gun and
continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30)
seconds.
4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool
for another two (2) minutes before the wiring lead is attached to the terminal.
5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify
operation.
Parts Block
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9463
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042405A Repair Grid Lines (Includes 0.7 Hr.
Time To Diagnose And Recheck)
042405B Replace Terminal (Includes 0.4 Hr.
Time To Diagnose And Recheck)
042405C Repair Grid Lines And 0.8 Hr.
Replace Terminal (Includes Time To Diagnose And Recheck)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7042006 28
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 9468
Heated Glass Element Relay: Testing and Inspection
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 9469
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
One Touch Window Down Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9474
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9475
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9476
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9477
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9478
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9479
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9480
One Touch Window Down Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9481
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9482
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9483
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9484
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9485
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9486
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9487
One Touch Window Down Module: Connector Views
Driver Door Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9488
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9489
One Touch Window Down Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9490
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions
> Page 9491
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > One Touch Window Down
Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 9492
One Touch Window Down Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch > Page 9501
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch > Page 9502
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Left Rear Window Switch > Page 9503
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Page 9504
Power Window Switch: Description and Operation
PRINCIPLES OF OPERATION
The driver power window one touch down operation is controlled by the Driver Door Module
(DDM), if equipped with remote keyless entry, or the one touch down module if not equipped with
remote keyless entry. The one touch down operation is requested of the module by momentarily
pressing the driver window down switch for 32 ms to 480 ms. The module uses the initial voltage
input from the down switch to begin one touch down operation. If the voltage input was less than
480 ms, the module will maintain the voltage supply to the motor down circuit. Circuit breaker 14
(20 A) supplies the power to the module for this operation. The module will maintain the operation
until: seven seconds expire.
- the module detects motor stalled by monitoring the current draw.
- a voltage input is received by the module on either the up or down switch circuits.
The ground for one touch down operation does not pass through the module. The ground is
supplied through the driver window switch as with normal operation. If the module continues to
detect voltage on the down circuit for more than 480 ms after initial activation, the module will not
affect operation. The down circuit through the module is a direct connection to the motor in its
normal state. This allows the driver window switch to control the motor for normal operation.
The passenger window motors are hardwired directly to the window regulator control switches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch
Power Window Switch: Testing and Inspection LR Window Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9507
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9508
Power Window Switch: Testing and Inspection Master Power Window Switch
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9509
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9510
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9511
Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9512
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > LR Window Control Switch > Page 9513
Power Window Switch: Testing and Inspection Right Rear Power Window Switch
Component Testing Procedure
Terminals
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 9514
Power Window Switch: Service and Repair
REMOVAL
1. Remove the switch bezel.
2. Remove the screws.
3. Disconnect the connector.
4. Remove the master window regulator control switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions
One Touch Window Down Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
- Power Distribution Diagrams
- System Diagrams
- Grounds Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9520
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9521
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9522
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9523
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9524
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9525
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9526
One Touch Window Down Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
- Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
- Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
- Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
- Use electrical test procedures to find the specific cause of the symptoms.
- The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
- Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
- Repair or replace the inoperative component.
Step 6. Verify the repair.
- Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9527
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9528
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
- Motors: disconnect motor connector (Connector C4).
- Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component.
- If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9529
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9530
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9531
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9532
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9533
One Touch Window Down Module: Connector Views
Driver Door Module
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9534
Driver's Door Module (C520)
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9535
One Touch Window Down Module: Electrical Diagrams
Diagram 57-1
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9536
Diagram 57-2
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9537
Diagram 57-3
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > One Touch Window Down Module <--> [Power Window
Control Module] > Component Information > Diagrams > Page 9538
One Touch Window Down Module: Service and Repair
REMOVAL
CAUTION: Prior to removal of module, it is necessary to upload module configuration information
to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damages may result.
2. Remove the driver door trim panel.
3. Remove the Driver Door Module (DDM).
1 Disconnect the electrical connector.
2 Remove the screws.
3. Release the locking tab.
INSTALLATION
CAUTION: Once the new module is installed, it is necessary to download the module configuration
information from the New Generation STAR (NGS) Tester into the new module.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information >
Specifications > Electrical Specifications
Power Window Motor: Electrical Specifications
No Load Window Regulator Electric Drive Current Draw 5 A
Or Less At 12.8 Volts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information >
Specifications > Electrical Specifications > Page 9543
Power Window Motor: Mechanical Specifications
Window Regulator Electric Drive Screws 89 in.lb
Window Regulator Motor to Regulator Screws 53 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and
Repair > Rear Door Window Motor
Power Window Motor: Service and Repair Rear Door Window Motor
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the rear door trim panel.
3. Remove the pull strap handle. 4. Remove the watershield.
5. Disconnect the connector.
6. Remove the rivets.
NOTE: Use care not to enlarge the sheet metal holes in the door inner panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and
Repair > Rear Door Window Motor > Page 9546
7. Remove the Torx (R) screws.
NOTE: Working through the access hole, remove the window regulator motor bracket from the
inner panel and slide the motor back to gain access to the screws.
8. Separate the window regulator motor from the window regulator and remove from the rear door.
INSTALLATION
1. Install the Torx (R) screws.
NOTE: Position the window regulator motor to the rear door electric window regulator and window
regulator motor mounting bracket.
2. Install the rivets.
NOTE: Position the window regulator motor mounting bracket to the inner panel.
- 1/4-20 x 1/2 inch bolt and 1/4-20 nut and washer assemblies or equivalent metric fasteners may
be used in place of the rivets.
3. Connect the connector. 4. Install the watershield. 5. Install the pull strap handle. 6. Install the
rear door trim panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and
Repair > Rear Door Window Motor > Page 9547
Power Window Motor: Service and Repair Front Door Window Motor
REMOVAL
1. Remove the front door trim panel. 2. Position the front door window glass in the full up position
and secure with tape. 3. Disconnect the battery ground cable.
4. Disconnect the connector.
5. Remove the rivets.
6. Remove the Torx (R) screws.
NOTE: Working through the access hole, remove the motor bracket from the inner panel and slide
the motor rear to the access hole in the door.
7. Separate the window regulator motor from the front door window regulator and remove it from
the front door.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and
Repair > Rear Door Window Motor > Page 9548
1. Install the screws.
NOTE: Position the window regulator motor to the front door window regulator.
2. Install the three rivets.
NOTE: Position the window regulator motor on the inner panel.
3. Connect the connector. 4. Connect the battery ground cable. 5. Remove the tape from the front
window. 6. Check the front door window glass for correct operation. 7. Install the front door trim
panel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Left Rear Window Switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Left Rear Window Switch > Page 9553
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Left Rear Window Switch > Page 9554
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Left Rear Window Switch > Page 9555
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Page 9556
Power Window Switch: Description and Operation
PRINCIPLES OF OPERATION
The driver power window one touch down operation is controlled by the Driver Door Module
(DDM), if equipped with remote keyless entry, or the one touch down module if not equipped with
remote keyless entry. The one touch down operation is requested of the module by momentarily
pressing the driver window down switch for 32 ms to 480 ms. The module uses the initial voltage
input from the down switch to begin one touch down operation. If the voltage input was less than
480 ms, the module will maintain the voltage supply to the motor down circuit. Circuit breaker 14
(20 A) supplies the power to the module for this operation. The module will maintain the operation
until: seven seconds expire.
- the module detects motor stalled by monitoring the current draw.
- a voltage input is received by the module on either the up or down switch circuits.
The ground for one touch down operation does not pass through the module. The ground is
supplied through the driver window switch as with normal operation. If the module continues to
detect voltage on the down circuit for more than 480 ms after initial activation, the module will not
affect operation. The down circuit through the module is a direct connection to the motor in its
normal state. This allows the driver window switch to control the motor for normal operation.
The passenger window motors are hardwired directly to the window regulator control switches.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch
Power Window Switch: Testing and Inspection LR Window Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9559
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9560
Power Window Switch: Testing and Inspection Master Power Window Switch
Component Testing Procedure
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9561
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9562
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9563
Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9564
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > LR Window Control Switch > Page 9565
Power Window Switch: Testing and Inspection Right Rear Power Window Switch
Component Testing Procedure
Terminals
Schematic
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 9566
Power Window Switch: Service and Repair
REMOVAL
1. Remove the switch bezel.
2. Remove the screws.
3. Disconnect the connector.
4. Remove the master window regulator control switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair
Back Window Glass: Service and Repair
REMOVAL
WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL
INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Disconnect the connectors, if equipped. 2. Remove the interior garnish mouldings.
3. Remove the rear window glass using a suitable suction tool.
NOTE: Use a long knife to cut any remaining urethane stringers.
4. Trim the urethane on the pinch weld.
NOTE: Clean around the pinch weld area to remove any dirt or foreign material that could
contaminate the existing urethane once it is trimmed.
5. Inspect the pinch weld for damaged metal, rust or foreign objects. Repair the pinch weld as
necessary.
NOTE: To avoid rust formation, take extreme care not to scratch or otherwise damage the pinch
weld.
INSTALLATION
1. Apply urethane metal primer WSB-M2G234-C or equivalent to any exposed or damaged metal
on the pinch weld.
NOTE: A minimum of ten minutes is required for the primer surface to dry.
2. Place the rear window glass inside up on a low, stable work surface.
NOTE: If a new rear window glass is to be installed, attach the new moulding to the edge of the
glass starting at the top center, then working out, then down the pillars and around the corners.
3. Clean the rear window glass with a non-alcohol based window cleaner. 4. Apply the Urethane
Glass Prep WSB-M5B280-C or equivalent to the rear window glass interior edges.
- Apply the Urethane Glass Prep WSB-M5B280-C or equivalent to the rear window glass interior
edges 21 mm (0.8 inch) wide along top and sides and 70 mm (2.75 inch) wide along the bottom.
- Wipe the rear window glass where the Urethane Glass Prep WSB-M5B280-C or equivalent has
been applied.
- Repeat the application in Steps 1 and 2.
NOTE: Wipe off the Urethane Glass Prep WSB-M5B280-C or equivalent immediately after application
because it flash dries. Two coats of the Urethane Glass Prep WSB-M5B280-C or equivalent must
be applied.
- Use a clean wool applicator to apply the Urethane Glass Prep WSB-M5B280-C or equivalent.
5. Align the rear window glass to the body.
- Place the rear window glass on the pinch weld.
- Center the rear window glass in the opening.
- Adjust the glass stops.
- Mark the rear window glass alignment on the glass and the body with tape or a grease pencil.
6. Remove the rear window glass. 7. Apply the Urethane Glass Primer WSB-M2G314-A or
equivalent to the interior edges of the rear window glass 21 mm (0.8 inch) wide along top
and sides and 70 mm (2.75 inch) wide along the bottom.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Page 9571
NOTE: Urethane Glass Primer WSB-M2G314-A or equivalent must be mixed thoroughly for even
pigmentation.
- Urethane Glass Primer WSB-M2G314-A or equivalent must cure for a minimum of five minutes.
8. Apply an even bead of Urethane Adhesive WSB-M2G316-B or equivalent around the entire
sheet metal flange on top of the existing bead of
urethane. The bead should be approximately 8 mm (0.314 inch) at the base and 14 mm (0.55 inch)
high and triangular in shape.
NOTE: The rear window glass must be installed before the adhesive skins over.
9. Install the rear window glass on the pinch weld. Align the rear window glass to the body using
the alignment marks.
CAUTION: When replacing urethane-installed parts, do not drive the vehicle until the urethane has
cured. At 21°C (70°F) and relative humidities above 50%, adequate cure time is typically 24 hours
(less at higher temperature and higher humidities). See detailed instructions provided by the
urethane manufacturer. Inadequate or incorrect curing can adversely affect the retention of the rear
window glass.
10. Inspect the rear window glass for air or water leaks through the urethane.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair
Front Door Window Glass: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Position the watershield out of the way.
1 Remove the speaker.
2 Disconnect the driver door module.
3 Position the watershield out of the way.
3. Remove the bolt. 4. Position the front door glass run front retainer forward.
5. Remove the rivets.
CAUTION: Do not attempt to forcibly remove the rivets as damage to the front door window glass
will result.
NOTE: Before removing rivets, it is necessary to place a suitable block support between the front door
window channel bracket and the door outer panel to help stabilize the front door window bracket
during rivet removal.
- Lower the front door window glass to gain access to the two front door window channel bracket
rivets.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair > Page 9575
6. Remove the front door window glass.
INSTALLATION
1. Position the front door window glass into the door frame. 2. Install two 1/4-inch rivets (use of
1/4-20 x 1 inch screw and washer assemblies and 1/4 inch-20 nut and washer are optional).
Tighten the nut (if
used) to 13 N.m (10 Lb-Ft).
NOTE: Align the front door window glass with the front door window channel bracket, if necessary.
3. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair
Quarter Window Glass: Service and Repair
REMOVAL
1. Remove the rear door trim panel.
2. Remove the pull strap handle.
3. Remove the watershield. 4. Remove the interior weather strip. 5. Remove the rear door window
glass.
6. Remove the rear door window garnish moulding.
7. Remove the exterior weatherstrip.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 9579
8. Remove the rear door top glass run and quarter window glass as an assembly.
NOTE: Pull the quarter glass forward to loosen the rear door top glass run assembly.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Make sure to install the quarter window glass into the glass channel.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair
Rear Door Window Glass: Service and Repair
REMOVAL
1. Remove the rear door trim panel.
2. Remove the pull strap handle. 3. Remove the watershield.
4. Remove the bolt.
5. Remove the rivets.
CAUTION: Do not attempt to forcibly remove the rivets as damage to the rear door window glass
may result prior to removing the rivet center pins, it is necessary to place a suitable block support
between the door outer panel and the rear door window channel bracket to stabilize the rear door
window glass during rivet removal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 9583
6. Remove the bolt.
7. Remove the rear door window glass.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair
Front Door Window Regulator: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Position the watershield out of the way.
1 Remove the speaker.
2 Remove the driver door module.
3 Position the watershield out of the way.
3. Remove the front door window glass.
4. Disconnect the connector.
5. Remove the rivets.
6. Remove the Torx (R) screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 9588
7. Remove the nuts. 8. Remove the regulator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications
Rear Door Window Regulator: Specifications
Upper Regulator Mounting Nuts 12 Nm
Rear Door Window Regulator Motor Screws 6 Nm
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications > Page 9592
Rear Door Window Regulator: Service and Repair
REMOVAL
1. Remove the rear door trim panel.
2. Remove the pull strap handle. 3. Remove the watershield. 4. Remove the rear door window
glass.
5. Disconnect the connector.
6. Remove the rivets.
7. Remove the nuts.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications > Page 9593
8. Remove the rear door window regulator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications
Window Track: Specifications
Door Glass Top Run Screws 9 ft.lb
Front Door Glass Run Front Retainer Screw 9 ft.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications >
Page 9597
Window Track: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Remove the interior weatherstrip. 3. Remove the front door window glass.
4. Remove the interior gamish moulding.
5. Remove the bolt.
6. Remove the exterior weatherstrip.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications >
Page 9598
7. Remove the door glass top run.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks
Windshield: Customer Interest Windshield - Water Leaks
Article No. 99-2-3
^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP
^ WINDSHIELD - SEALING - SERVICE TIP
FORD: 1995-97 PROBE, THUNDERBIRD
1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND
MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER
LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER,
F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION,
MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or
a void in the production sealer somewhere around the periphery of the windshield.
ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the
periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip
removal where necessary.
NOTE
DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY
BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO
ENSURE REPAIR OF THE LEAK.
The following is the labor operation to be used for this repair and a chart providing Windshield
Sealing Labor Times:
^ 03100B
PART NUMBER PART NAME
F8AZ-19554-CA Liquid Butyl Sealer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 9607
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 110000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks
Windshield: All Technical Service Bulletins Windshield - Water Leaks
Article No. 99-2-3
^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP
^ WINDSHIELD - SEALING - SERVICE TIP
FORD: 1995-97 PROBE, THUNDERBIRD
1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS
LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND
MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER
LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER,
F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION,
MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES
ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or
a void in the production sealer somewhere around the periphery of the windshield.
ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the
periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip
removal where necessary.
NOTE
DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY
BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO
ENSURE REPAIR OF THE LEAK.
The following is the labor operation to be used for this repair and a chart providing Windshield
Sealing Labor Times:
^ 03100B
PART NUMBER PART NAME
F8AZ-19554-CA Liquid Butyl Sealer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 9613
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 110000
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Page 9614
Windshield: Service and Repair
SPECIAL TOOL(S)
REMOVAL
1. Remove the windshield wiper pivot arms.
WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT INJURY.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
2. Remove the cowl top vent panel. 3. Remove the visors. 4. Remove the windshield garnish
mouldings. 5. Remove the instrument panel upper finish panel. 6. Remove the interior rear view
mirror. 7. Partially drop the headliner near the windshield opening and block with suitable material.
8. Using the special tool, cut the adhesive. Refer to manufacturer's instructions when using the
tool.
CAUTION: Cover the instrument panel in order to prevent possible damage.
9. Remove the windshield and moulding assembly using a suitable suction tool and place on a
stable work surface.
10. Trim any remaining urethane on the pinch weld to within 1.0 and 2.0 mm (0.04 and 0.08 inch)
thickness.
NOTE: Clean the area around the existing urethane prior to trimming.
11. Check the pinch weld sealing area for damaged sheet metal, rust or foreign objects which may
cause glass breakage. Repair the sheet metal if
necessary.
INSTALLATION
1. Apply Urethane Metal Primer ESB-M2G234-A or equivalent to any exposed or damaged metal
on the pinch weld.
NOTE: A minimum of ten minutes is required for the primer surface to dry.
2. Clean the windshield glass with a non-alcohol based window cleaner. 3. Using a wool applicator,
wipe the interior glass edge with Urethane Glass Prep WSB-M5B280-C 21 mm (0.8 inch) wide
along the top and sides
and 70 mm (2.75 inch) wide along the bottom. Wipe off the glass prep and repeat the glass prep
application.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Page 9615
NOTE: Wipe off the urethane glass prep WSB-M5B280-C or equivalent immediately after
application because it flash dries. Two coats of the Urethane Glass Prep must be applied.
4. Align the windshield glass to the body.
^ Place the windshield glass to the body.
^ Center the windshield glass in the opening.
^ Adjust the windshield stops.
^ Mark the windshield glass alignment on the glass and the body.
5. Remove the windshield glass from the vehicle and place it back onto the work table. 6.
Thoroughly shake and stir the Urethane Glass Primer WSH-M2G314-B or equivalent to make sure
of even pigment mixing. 7. Using a clean wool applicator, apply primer to interior glass edges 21
mm (0.8 inch) along the top and sides and 70 mm (2.75 inch) wide along
the bottom.
NOTE: Allow a minimum of five minutes for the glass primer to dry.
8. Install the instrument panel upper finish panel. 9. Apply the new Urethane Adhesive
WSB-M2G316-B or equivalent in an even bead onto the existing urethane on the pinch weld.
NOTE: ^
Leave a door window slightly open until the adhesive is cured.
^ Apply the new urethane on top of the existing material on the pinch weld.
^ The newly-applied bead should be triangular in shape.
10. Install the windshield glass on the pinch weld, then align the windshield glass to the body using
the alignment marks. 11. Install the cowl top vent panel. 12. Install the windshield pivot arms. 13.
Install the headliner. 14. Install the visors. 15. Install the windshield garnish mouldings. 16. Install
the interior rear view mirror. 17. Check the installation for air and water leaks through the urethane
seal.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Page 9621
Wiper Control Module: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
2. Remove the tunnel brace trim cover.
1 Remove pin-type retainers.
2 Remove the tunnel brace trim cover.
3. Position the instrument panel ash receptacle aside.
1 Remove the screws.
2 Position the instrument panel ash receptacle aside.
4. Remove the instrument panel ash receptacle assembly.
1 Disconnect the electrical connector.
2 Remove the instrument panel ash receptacle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Page 9622
5. Remove the windshield wiper control module.
1 Remove the screw.
2 Disconnect the electrical connector.
3 Remove the windshield wiper control module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation
Windshield Washer Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 9627
Windshield Washer Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 9628
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 9629
Windshield Washer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 9630
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation > Page 9631
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation
Wiper Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation > Page 9635
Wiper Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation > Page 9636
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation > Page 9637
Wiper Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation > Page 9638
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation > Page 9639
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information >
Description and Operation
Washer Fluid Level Indicator: Description and Operation
The LOW WASHER FLUID warning indicator illuminates when windshield washer fluid level is
below specified levels or a concern is detected in the windshield washer fluid level circuit. During
prove-out, when a concern is detected or the windshield washer fluid level is low, an audible tone
will sound and the LOW WASHER FLUID warning indicator will flash on and off for five seconds.
The LOW WASHER FLUID warning indicator will then remain illuminated until the concern is
corrected or the windshield washer fluid level is raised above specified level.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair
Windshield Washer Pump: Service and Repair
REMOVAL
1. Remove the air cleaner assembly.
2. Position the pump and reservoir aside.
1 Remove the bolts.
2 Position the pump and reservoir aside.
3. Remove the washer pump and reservoir.
1 Disconnect the electrical connectors.
2 Disconnect the washer hose.
3 Remove the pump and reservoir.
WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL WHICH IS
POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON LABEL OF
WASHER SOLUTION CONTAINER.
NOTE: Windshield washer fluid should be collected in a container after the windshield washer hose
is disconnected.
4. Remove the washer pump.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair
Windshield Washer Reservoir: Service and Repair
REMOVAL
1. Remove the air cleaner assembly.
2. Position the pump and reservoir aside.
1 Remove the bolts.
2 Position the pump and reservoir aside.
3. Remove the washer pump and reservoir.
1 Disconnect the electrical connectors.
2 Disconnect the washer hose.
3 Remove the pump and reservoir.
WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL WHICH IS
POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON LABEL OF
WASHER SOLUTION CONTAINER.
NOTE: Windshield washer fluid should be collected in a container after the windshield washer hose
is disconnected.
4. Remove the washer pump.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Description and Operation
Windshield Washer Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Description and Operation > Page 9652
Windshield Washer Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Description and Operation > Page 9653
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Description and Operation > Page 9654
Windshield Washer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Description and Operation > Page 9655
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Description and Operation > Page 9656
Special Tools
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications
Wiper Arm: Specifications
LH Wiper Pivot Arm Installation Position 2-26 mm
RH Wiper Pivot Arm Installation Position 5-33 mm
Mounting Arm and Pivot Shaft Bolts 106 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page
9660
Wiper Arm: Adjustments
NOTE: The windshield wiper pivot arm and windshield wiper blade assemblies are positioned using
a key and keyway. If adjustment is required, use the following procedure:
1. Remove the wiper pivot arm. 2. Remove the key from the wiper pivot arm. 3. Cycle the wiper
motor to the park position.
4. Install the LH wiper pivot arm to the specified position above the ramp stop.
5. Install the RH wiper pivot arm to the specified position above the ramp stop. 6. Lower the wiper
pivot arms to the ramp stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page
9661
Wiper Arm: Service and Repair
REMOVAL
1. Remove the pivot arm.
1 Lift the pivot arm slightly off the glass.
2 Release the locking tab and rest the pivot arm on the locking tab.
3 Remove the pivot arm.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When installing the pivot arm on the pivot shaft, it is necessary to align the key on the pivot
arm with the key on the pivot shaft.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments
Wiper Blade: Adjustments
NOTE: The windshield wiper pivot arm and windshield wiper blade assemblies are positioned using
a key and keyway. If adjustment is required, use the following procedure:
1. Remove the wiper pivot arm. 2. Remove the key from the wiper pivot arm. 3. Cycle the wiper
motor to the park position.
4. Install the LH wiper pivot arm to the specified position above the ramp stop.
5. Install the RH wiper pivot arm to the specified position above the ramp stop. 6. Lower the wiper
pivot arms to the ramp stops.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Page 9668
Wiper Control Module: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
2. Remove the tunnel brace trim cover.
1 Remove pin-type retainers.
2 Remove the tunnel brace trim cover.
3. Position the instrument panel ash receptacle aside.
1 Remove the screws.
2 Position the instrument panel ash receptacle aside.
4. Remove the instrument panel ash receptacle assembly.
1 Disconnect the electrical connector.
2 Remove the instrument panel ash receptacle.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Page 9669
5. Remove the windshield wiper control module.
1 Remove the screw.
2 Disconnect the electrical connector.
3 Remove the windshield wiper control module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips
Windshield Wiper Motor: Technical Service Bulletins Wipers/Washers - Wiper Motor Transfer Tips
Article No. 03-7-2
04/14/03
ELECTRICAL - FRONT WIPER MOTOR - MOUNTING BRACKET AND DEPRESSED PARK OUT
ARM - TRANSFER SERVICE TIPS
FORD: 1987-1995 TAURUS 1987-2002 CROWN VICTORIA
LINCOLN: 1987-1997 TOWN CAR 1988-1997 CONTINENTAL 1993-1998 MARK VIII
MERCURY: 1987-1995 SABLE 1987-2002 GRAND MARQUIS
Article 02-10-1 is being republished in its entirety to update the Service Procedure.
ISSUE Motorcraft remanufactured front wiper motors do not include the mounting bracket or
depressed park output arm. The mounting bracket and depressed park output arm must be
transferred from the old wiper motor to the replacement wiper motor. Care must be taken to ensure
proper orientation of the windlatch assembly and depressed park output arm.
ACTION The front wiper motor mounting bracket and output arm must be removed from the old
front wiper motor and installed on the remanufactured wiper motor if wiper motor replacement is
required. Refer to the following service information for details.
SERVICE PROCEDURE
Disassembly:
1. Using a small flat bladed screwdriver, carefully remove the plastic output arm dust cover from
the old wiper motor output arm to expose the output arm hold down bolt.
NOTE
THE DUST COVER WILL BE REINSTALLED DURING ASSEMBLY.
2. Remove the output arm attaching bolt.
3. Using a small light hammer, gently tap the backside of the output arm to remove the output arm
from the wiper motor output shaft. Carefully observe the orientation of the plastic windlatch slide.
NOTE
TAKE CARE NOT TO DAMAGE THE PLASTIC WINDLATCH SLIDE OR BRACKET. IT IS NOT
NECESSARY TO REMOVE THE PLASTIC WINDLATCH SLIDE OR METAL GUIDE FROM THE
WIPER MOTOR MOUNTING BRACKET.
4. Remove the three (3) 8 mm wiper motor mounting bracket attaching bolts.
5. Remove the wiper motor bracket.
Assembly:
1. Position and align the old wiper motor mounting bracket onto the new wiper motor.
2. Reinstall the three wiper motor mounting bracket bolts and torque to 108-156 Lb-in. (13-17 N.m).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9674
3. Verify that the plastic windlatch slide is positioned so that it can move an equal distance beyond
both ends of the depressed park windlatch guide bracket. Make sure the tab on the windlatch is
oriented in the proper direction for the specific application (Figure 1, views A and C).
4. Apply a thin film of Silicone Brake Caliper Grease (Motorcraft Part XG-3-A) to the mating
surfaces of the plastic windlatch slide and the output arm.
5. Install the output arm onto the wiper motor output shaft according to the specific application
(Figure 1, views B and D).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9675
NOTE
THE OUTPUT SHAFT AND ARM ARE KEYED FOR PROPER ORIENTATION.
6. Reinstall the output arm bolt and torque to 132-180 Lb-in. (15-20 N.m).
7. Reinstall the plastic output arm dust cover.
8. Rotate the output arm slowly clockwise one full turn by hand, then turn the output arm by hand
counter-clockwise to seat the detent in the output arm against the stop on the plastic windlatch
slide.
9. Position the vehicle wiper arm linkage so that the wiper blades are at the bottom of the
windshield, just above the parked position.
10. Install the wiper motor in the vehicle and connect the wiper arm linkage per the procedures
outlined in Section 01-16 or Section 501-16 Wiper and Washer Systems - Removal and
Installation, of the appropriate model year Workshop Manual.
TROUBLESHOOTING:
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-10-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 202000, 290000
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Page 9676
Windshield Wiper Motor: Specifications
Windshield Wiper Motor Bolts 89 in.lb
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Page 9677
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Page 9678
Windshield Wiper Motor: Testing and Inspection
CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper
operations. Failure to do so may result in damage to the motor magnets and will make the
windshield wiper motor inoperative. Rough handling of a new windshield wiper motor may also
damage the motor magnets.
Use Alternator, Regulator, and Starter Tester (ARBST) to test the wiper motor on the vehicle.
To test the wiper motor, disconnect the wiper mounting arm and pivot shaft from the wiper motor.
Disconnect the wiper motor connector. Connect the (A) green lead from the (B) ARBST to the
positive post. Connect the (C) red lead from the tester to the wiper motor (D) common brush Pin 5
component side.
Test the low speed mode by connecting a (E) cable from the battery negative post to the low speed
brush Pin 6 and measure the current draw. If the current draw is greater than 3.5 amperes, install a
new wiper motor.
Test the high speed mode by connecting a cable from the battery negative post to the (G) high
speed brush Pin 7 component side and measure the current draw. If the current draw is greater
than 5.5 amperes, install a new wiper motor.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component
Information > Technical Service Bulletins > Page 9679
Windshield Wiper Motor: Service and Repair
REMOVAL
1. Remove the mounting arm and pivot shaft assembly. 2. Remove the windshield wiper motor
cover.
3. Disconnect the wiper motor linkage.
1 Remove the clip.
2 Disconnect the linkage.
4. Remove the windshield wiper motor.
1 Remove the bolts.
2 Remove the motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical
Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips
Wiper Motor Linkage: Technical Service Bulletins Wipers/Washers - Wiper Motor Transfer Tips
Article No. 03-7-2
04/14/03
ELECTRICAL - FRONT WIPER MOTOR - MOUNTING BRACKET AND DEPRESSED PARK OUT
ARM - TRANSFER SERVICE TIPS
FORD: 1987-1995 TAURUS 1987-2002 CROWN VICTORIA
LINCOLN: 1987-1997 TOWN CAR 1988-1997 CONTINENTAL 1993-1998 MARK VIII
MERCURY: 1987-1995 SABLE 1987-2002 GRAND MARQUIS
Article 02-10-1 is being republished in its entirety to update the Service Procedure.
ISSUE Motorcraft remanufactured front wiper motors do not include the mounting bracket or
depressed park output arm. The mounting bracket and depressed park output arm must be
transferred from the old wiper motor to the replacement wiper motor. Care must be taken to ensure
proper orientation of the windlatch assembly and depressed park output arm.
ACTION The front wiper motor mounting bracket and output arm must be removed from the old
front wiper motor and installed on the remanufactured wiper motor if wiper motor replacement is
required. Refer to the following service information for details.
SERVICE PROCEDURE
Disassembly:
1. Using a small flat bladed screwdriver, carefully remove the plastic output arm dust cover from
the old wiper motor output arm to expose the output arm hold down bolt.
NOTE
THE DUST COVER WILL BE REINSTALLED DURING ASSEMBLY.
2. Remove the output arm attaching bolt.
3. Using a small light hammer, gently tap the backside of the output arm to remove the output arm
from the wiper motor output shaft. Carefully observe the orientation of the plastic windlatch slide.
NOTE
TAKE CARE NOT TO DAMAGE THE PLASTIC WINDLATCH SLIDE OR BRACKET. IT IS NOT
NECESSARY TO REMOVE THE PLASTIC WINDLATCH SLIDE OR METAL GUIDE FROM THE
WIPER MOTOR MOUNTING BRACKET.
4. Remove the three (3) 8 mm wiper motor mounting bracket attaching bolts.
5. Remove the wiper motor bracket.
Assembly:
1. Position and align the old wiper motor mounting bracket onto the new wiper motor.
2. Reinstall the three wiper motor mounting bracket bolts and torque to 108-156 Lb-in. (13-17 N.m).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical
Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9684
3. Verify that the plastic windlatch slide is positioned so that it can move an equal distance beyond
both ends of the depressed park windlatch guide bracket. Make sure the tab on the windlatch is
oriented in the proper direction for the specific application (Figure 1, views A and C).
4. Apply a thin film of Silicone Brake Caliper Grease (Motorcraft Part XG-3-A) to the mating
surfaces of the plastic windlatch slide and the output arm.
5. Install the output arm onto the wiper motor output shaft according to the specific application
(Figure 1, views B and D).
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical
Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9685
NOTE
THE OUTPUT SHAFT AND ARM ARE KEYED FOR PROPER ORIENTATION.
6. Reinstall the output arm bolt and torque to 132-180 Lb-in. (15-20 N.m).
7. Reinstall the plastic output arm dust cover.
8. Rotate the output arm slowly clockwise one full turn by hand, then turn the output arm by hand
counter-clockwise to seat the detent in the output arm against the stop on the plastic windlatch
slide.
9. Position the vehicle wiper arm linkage so that the wiper blades are at the bottom of the
windshield, just above the parked position.
10. Install the wiper motor in the vehicle and connect the wiper arm linkage per the procedures
outlined in Section 01-16 or Section 501-16 Wiper and Washer Systems - Removal and
Installation, of the appropriate model year Workshop Manual.
TROUBLESHOOTING:
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-10-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 202000, 290000
Disclaimer
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical
Service Bulletins > Page 9686
Wiper Motor Linkage: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the cowl top vent panel.
3. Position the evaporative emission canister purge valve aside.
1 Remove the nuts.
2 Position the evaporative emission canister purge valve aside.
4. Position the mounting arm and pivot shaft aside.
1 Remove the bolts.
2 Position the mounting arm and pivot shaft aside.
5. Remove the mounting arm and pivot shaft.
^ Disconnect the electrical connector.
^ Disconnect the washer supply hose.
NOTE: If necessary, remove the windshield wiper motor.
INSTALLATION
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical
Service Bulletins > Page 9687
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and
Operation
Wiper Switch: Description and Operation
The steering column switches consist of the following components: ^
The multifunction switch controls the following functions: turn signals
- headlamp dimmer
- headlamp flash-to-pass
- hazard warnings-cornering lamps
- windshield washer/wipers
^ Ignition switch
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and
Operation > Page 9691
Wiper Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and
Operation > Page 9692
Schematic
NOTE: For additional testing relating to the Multifunction Switch, please see the procedures at
Ignition Switch / Testing and Inspection.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and
Operation > Page 9693
Wiper Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the shrouds.
5. Remove the multifunction switch.
1 Remove the screws.
Ford Crown Victoria Workshop Manual (V8-4.6L CNG SOHC VIN 9 (1999))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and
Operation > Page 9694
2 Disconnect the electrical connectors.
3 Remove the switch.
Installation
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn its strategy.
To install, reverse the removal procedure.